Category: Filament

I love that 3d printing allows you to create physical objects from digital models. Despite what I thought when I got my first 3d printer, it is not as simple as pressing a button and watching your design come to life. There are many factors that affect the quality and outcome of your 3D prints, and one of the most important ones is the configuration settings.

Configuration settings are the parameters that control how your 3D printer operates, such as the temperature, speed, layer height, infill, retraction, and more. These settings can vary depending on the type of printer, filament, model, and desired result. They can also interact with each other in complex ways, so changing one setting can affect another.

One of the most common problems that 3D printing enthusiasts face is poor bed adhesion. This means that the first layer of your print does not stick to the print bed, causing it to warp, curl, or detach. This can ruin your entire print and waste time and material. There are many possible causes for poor bed adhesion, such as incorrect bed temperature, nozzle height, leveling, or surface preparation. However, even if you have all these factors right, you may still encounter this issue if your other configuration settings are not optimal.

For example, if your print speed is too high, your extruder may not be able to keep up with the demand and under-extrude filament. This can result in gaps or thin spots in your first layer, which can compromise its adhesion. Similarly, if your retraction settings are too aggressive, you may experience oozing or stringing, which can interfere with the smoothness and consistency of your first layer. If your layer height is too large or your infill is too sparse, you may not have enough material to form a solid base for your print.

It is essential to understand how all of your configuration settings work together and how they affect the quality of your 3D prints. You should always test and calibrate your printer before starting a new project, and adjust your settings according to the specific requirements of your model and filament. You should also use slicing software that allows you to preview and fine-tune your settings before sending them to your printer. By doing so, you can avoid common pitfalls and achieve successful 3D prints every time.

Calibration – Check

Go to print – big goopy mess

Change nozzle – Check

Calibration – Check

repeat

After a lot of frustration I saw the wires for my part cooling fan pop out of the connector and I immediately knew what the problem was. Ugh. I had spent so much time diagnosing the wrong issue. The wires were in enough that they looked like they were secure, but out enough that they intermittently got disconnected. So, when I would print I would sometimes end up with heat creep or a big goopy mess of filament.

Bought 500 JST connectors on Amazon for $8.99 and my problem is solved.

Lessons learned (or relearned):

  • the root cause isn’t always immediately obvious
  • check everything
  • if you’ve replaced the nozzle 3 times and you still have the same problem, the problem likely isn’t the nozzle

The world of 3D printing has revolutionized manufacturing and design processes across industries. One key factor that significantly impacts the quality and reliability of 3D printed objects is thermal stability. I want to explore why thermal stability holds immense importance in the realm of 3D printing.

3D printing, also known as additive manufacturing, is a process that involves creating three-dimensional objects by layering materials based on a digital design. The success of 3D printing lies in achieving precise control over various parameters, including temperature. Thermal stability, the ability of a system to maintain a consistent temperature, plays a crucial role in ensuring the accuracy, structural integrity, and overall quality of the final printed objects.

Different 3D printing technologies utilize various materials such as thermoplastics, metals, resins, and composites. Each material has specific thermal characteristics that must be carefully managed during the printing process. Achieving thermal stability allows for precise control over the material’s melting point, viscosity, shrinkage, and curing reactions, ensuring optimal results.

Thermal stability is paramount in preventing warping and deformation in 3D printed objects. When materials cool too rapidly or unevenly, they can contract unevenly, leading to warping, curling, or cracking. Maintaining a stable and controlled printing environment, including the temperature of the build plate and the surrounding atmosphere, helps mitigate these issues and ensures dimensional accuracy.

Thermal stability directly affects the print quality and resolution of 3D printed objects. Variations in temperature can cause inconsistent material flow, resulting in uneven layer deposition, surface imperfections, or even failed prints. A stable and controlled temperature environment allows for consistent material flow, precise layering, and better adhesion between layers, ultimately leading to higher print quality and resolution.

In 3D printing, optimizing print speed is essential to increase efficiency and reduce production time. However, pushing the limits of print speed without considering thermal stability can lead to compromised print quality. Maintaining the appropriate temperature range for the material being used ensures that it flows smoothly and solidifies properly, enabling faster and more efficient printing without sacrificing quality.

Support structures play a vital role in 3D printing, especially when printing complex geometries or objects with overhangs. Thermal stability aids in the controlled and gradual cooling of the printed layers, allowing for the proper formation and removal of support structures. This process helps maintain the structural integrity of the printed object while minimizing the need for excessive supports or post-processing.

What makes a good 3D printer extruder?

A 3D printer extruder is the part of the printer that pushes the filament through a nozzle and deposits it on the build plate. The extruder is responsible for the quality and accuracy of the printed object, as well as the speed and reliability of the printing process. Therefore, choosing a good 3D printer extruder is essential for getting the best results from your 3D printing projects.

There are many factors that affect the performance of a 3D printer extruder, such as:

  • The type of filament: Different filaments have different properties, such as melting temperature, viscosity, flexibility, and strength. The extruder should be compatible with the filament you want to use, and be able to handle its characteristics without clogging, jamming, or breaking.
  • The design of the extruder: There are two main types of extruders: direct drive and Bowden. A direct drive extruder has the motor mounted directly on the nozzle, which reduces the distance and friction between the filament and the nozzle. This allows for more precise and consistent extrusion, especially with flexible or brittle filaments. However, a direct drive extruder also adds more weight and inertia to the print head, which can affect the speed and accuracy of the printer. A Bowden extruder has the motor mounted away from the nozzle, and uses a tube to guide the filament to the nozzle. This reduces the weight and inertia of the print head, which enables faster and smoother printing. However, a Bowden extruder also introduces more friction and slack in the filament path, which can cause under-extrusion, over-extrusion, or stringing, especially with flexible or soft filaments.
  • The quality of the components: The components of the extruder, such as the motor, the gears, the bearings, the nozzle, and the heat sink, should be made of durable and high-quality materials that can withstand high temperatures, pressures, and wear. The components should also be well-aligned and calibrated to ensure smooth and accurate extrusion.
  • The ease of use and maintenance: The extruder should be easy to install, adjust, and clean. It should also have features that make it more convenient and user-friendly, such as a filament sensor, a cooling fan, a dual extruder option, or a quick-release mechanism.

Maybe you’re just curious, maybe you’re looking to upgrade your extruder, or maybe you’re having random issues with your current extruder. In any case, I hope that these things help you.

Heat creep is a phenomenon that affects 3D printers, especially those that use a direct drive extruder. It occurs when the heat from the hot end travels up the filament and melts it before it reaches the nozzle, causing clogs, jams, and poor print quality. In this blog post, we will explore the causes of heat creep and how to prevent it.

One of the main causes of heat creep is poor cooling of the hot end. The hot end consists of a heater block, a heat break, and a heat sink. The heater block heats up the filament to melt it, the heat break transfers the heat to the heat sink, and the heat sink dissipates the heat with a fan. If the fan is not working properly, or if the heat sink is dirty or poorly designed, the heat will not be removed efficiently and will travel up the filament.

Another cause of heat creep is using a filament that has a low melting point or a high thermal conductivity. Some filaments, such as PLA, ABS, or PETG, have lower melting points than others, such as nylon or polycarbonate. This means that they can soften or melt at lower temperatures, which makes them more prone to heat creep. Similarly, some filaments have higher thermal conductivity than others, which means that they can transfer heat more easily along their length. This can also cause them to soften or melt before reaching the nozzle.

A third cause of heat creep is printing at high temperatures or speeds. Printing at high temperatures can increase the amount of heat generated by the heater block and make it harder for the heat sink to cool it down. Printing at high speeds can also increase the friction between the filament and the extruder gears, which can generate more heat and cause the filament to deform. Both of these factors can contribute to heat creep and affect the print quality.

To prevent heat creep, there are several steps that you can take. First, you should check your cooling fan and make sure that it is working properly and blowing air towards the heat sink. You should also clean your heat sink regularly and remove any dust or debris that might block the airflow. Second, you should choose a filament that has a high melting point and a low thermal conductivity, or adjust your printing temperature and speed accordingly. You should also use a good quality filament that does not have any impurities or inconsistencies that might affect its properties. Third, you should calibrate your extruder and make sure that it is not over-extruding or under-extruding filament. You should also use a retraction setting that minimizes stringing and oozing without causing too much pressure in the nozzle.

By following these tips, you can avoid heat creep and improve your 3D printing experience. Heat creep is a common problem that can ruin your prints and damage your printer, but it can be prevented with proper maintenance and settings. If you have any questions or comments about heat creep, feel free to leave them below.

If you are a 3D printing enthusiast, you may have encountered a frustrating problem: your nozzle seems to be clogged and no filament comes out. You try to clean it, replace it, or even upgrade it, but nothing works. What is going on?

The answer may surprise you: your nozzle may not be clogged at all, but rather your temperature may be too low. How can this happen? Let me explain.

When you print with a 3D printer, you need to heat up the filament to a certain temperature so that it can melt and flow through the nozzle. This temperature varies depending on the type of filament you use, but it is usually around 200°C for PLA and 230°C for ABS.

However, if your temperature is too low, the filament may not melt enough to flow smoothly. Instead, it may form a thick and sticky paste that accumulates inside the nozzle and prevents more filament from coming out. This can look like a clog, but it is actually a temperature issue.

How can you tell the difference? There are some signs that can help you diagnose the problem:

  • If your nozzle is clogged, you may hear a clicking sound from the extruder as it tries to push the filament through.
  • If your temperature is too low, you may see the filament curling up or forming blobs around the nozzle as it comes out.
  • If your nozzle is clogged, you may need to use a needle or a wire to clear it out.
  • If your temperature is too low, you may need to increase it by 5-10°C and try again.

To prevent this problem from happening in the future, you should always check the recommended temperature for your filament and make sure your printer is calibrated correctly. You should also avoid printing in cold or drafty environments that can affect the temperature of your nozzle.

I hope this blog post was helpful and informative. Happy printing!

If you are a 3D printing enthusiast, you may have encountered the frustrating problem of a clogged nozzle. This can happen when the filament gets stuck or melted inside the nozzle, preventing the extruder from pushing out more material. A clogged nozzle can ruin your print and waste your time and filament.

But what if the problem is not really a clogged nozzle, but something else? I will explain how improper tension on the extruder can masquerade as a clogged nozzle, and how to fix it.

The extruder is the part of the 3D printer that feeds the filament into the hot end, where it is melted and extruded through the nozzle. The extruder has a spring-loaded mechanism that applies pressure on the filament, pushing it against a drive gear or a hobbed bolt. This pressure is called tension, and it is essential for the extruder to work properly.

If the tension is too low, the drive gear or the hobbed bolt may slip on the filament, causing under-extrusion or skipping steps. This can result in gaps, holes, or weak layers in your print. If the tension is too high, the drive gear or the hobbed bolt may dig into the filament, causing over-extrusion or grinding. This can result in blobs, strings, or jams in your print.

Both under-extrusion and over-extrusion can look like a clogged nozzle, because they affect the amount and quality of material that comes out of the nozzle. However, a clogged nozzle is usually caused by a different issue, such as a dirty nozzle, a partial blockage, or a heat creep.

So how can you tell if your problem is really a clogged nozzle, or an improper tension on the extruder? Here are some tips:

  • Check your filament. If you see signs of grinding or slipping on the filament, such as flat spots, gouges, or dust, then your tension is likely too high or too low.
  • Check your extruder. If you hear clicking or popping noises from the extruder, then your tension is likely too high or too low.
  • Check your nozzle. If you see material oozing out of the nozzle when it is not printing, then your tension is likely too high. If you see no material coming out of the nozzle when it is printing, then your tension is likely too low.
  • Do a cold pull. A cold pull is a technique to clean your nozzle by heating it up, inserting a piece of filament, letting it cool down, and then pulling it out with force. If you see a clean tip on the filament after doing a cold pull, then your nozzle is not clogged.
  • Adjust your tension. Depending on your extruder model, you may have a screw, a knob, or a lever to adjust the tension on the filament. You want to find a balance between too much and too little pressure. A good rule of thumb is to make sure that the drive gear or the hobbed bolt leaves slight marks on the filament, but not deep enough to damage it.

Volumetric flow is a concept that relates to how much material a 3D printer can extrude in a given time. It is usually measured in cubic millimeters per second (mm³/s) and depends on factors such as the nozzle diameter, the extrusion temperature, and the type of filament being used.

Volumetric flow is important for 3D printing because it affects both the quality and the speed of the printing process. If the volumetric flow is too low, the printer may not be able to fill the gaps between the layers, resulting in weak or incomplete prints. If the volumetric flow is too high, the printer may over-extrude, causing blobs, stringing, or clogging.

To achieve optimal volumetric flow, one needs to calibrate the flow rate (also known as extrusion multiplier) in the slicer settings. This is a factor that adjusts how much filament the printer pushes through the nozzle. The flow rate can be calibrated by printing a test object with known dimensions and measuring its actual dimensions with calipers. The flow rate can then be adjusted until the measured dimensions match the expected ones.

Alternatively, one can use a volumetric flow calculator to estimate the optimal flow rate based on the nozzle diameter, the filament diameter, and the maximum extrusion temperature. This can save time and material by avoiding trial-and-error prints. However, this method may not account for variations in filament quality or environmental conditions, so it is recommended to verify the results with a test print.

Volumetric flow is also relevant for volumetric 3D printing, a technique that creates objects by solidifying a whole resin volume with light beams. This method can produce complex shapes with high resolution and smooth surfaces without requiring support structures or layer-by-layer fabrication. However, this method also requires precise control of the volumetric flow rate to avoid over- or under-exposure of the resin.

What to Check for on Your 3D Printer Nozzle

The first thing you should do is inspect your nozzle visually. Look for any signs of damage, such as cracks, dents, or scratches. If you see any, you should replace your nozzle.

Next, you should check if your nozzle is clean and free of any debris or filament residue. To clean your nozzle, you can use a brass brush or a needle to gently remove any stuck material. You can also heat up your nozzle and wipe it.

Finally, you should check if your nozzle is aligned with your print bed.

How to Maintain Your 3D Printer Nozzle

To keep your nozzle in good condition, you should perform some regular maintenance tasks. Here are some tips:

  • Clean your nozzle after every print or before changing filaments. This will prevent clogging and filament jams.
  • Use high-quality filaments that are compatible with your nozzle size and material type. Avoid using abrasive filaments, such as metal-filled or glow-in-the-dark ones, unless you have a hardened steel nozzle.
  • Store your filaments in a dry and cool place. Moisture and heat can degrade your filaments and cause extrusion issues.
  • Replace your nozzle when it wears out or gets damaged. A worn-out nozzle can have a larger or irregular diameter, which can affect the accuracy and quality of your prints.

How to Calibrate Your 3D Printer Nozzle

To get the best results from your 3D printer, you should calibrate your nozzle regularly. Calibration involves setting the correct nozzle temperature, flow rate, and retraction settings for your filament type and print quality. Here are some steps:

  • Find the recommended temperature range for your filament type and brand. You can usually find this information on the filament spool or the manufacturer’s website.
  • Heat up your nozzle to the lowest temperature in the range and extrude some filament. Observe how the filament comes out of the nozzle. It should be smooth and consistent, without any bubbles, curls, or strings.
  • Increase the temperature by 5°C increments and repeat the extrusion test until you find the optimal temperature for your filament. The optimal temperature is the one that gives you the best extrusion quality without causing overheating or oozing.
  • Find the recommended flow rate for your filament type and brand. You can usually find this information on the filament spool or the manufacturer’s website.
  • Print a calibration cube or a single-wall vase with 100% infill and no top or bottom layers. Measure the wall thickness with a caliper and compare it to the expected value (usually 0.4 mm for a 0.4 mm nozzle).
  • Adjust the flow rate in your slicer software until the wall thickness matches the expected value.
  • Find the recommended retraction settings for your filament type and brand.
  • Print a retraction test model that has multiple towers with gaps between them. Observe how much stringing occurs between the towers.
  • Adjust the retraction distance and speed in your slicer software until you minimize stringing without causing under-extrusion or blobs.

Sometimes the extruder gear is clicking or skipping. This can affect the quality of your prints and cause under-extrusion, blobs, or gaps in the layers. This can be difficult to diagnose because the root cause is often at the other side of the printer.

The extruder gear is the part that pushes the filament into the hot end, where it is melted and deposited onto the build plate. The extruder gear has teeth that grip the filament and rotate to feed it. Sometimes, the extruder gear can click or skip, meaning that it slips on the filament and fails to push it forward. This can happen for several reasons, such as:

  • The nozzle is too close to the build plate, causing too much back pressure and preventing the filament from flowing out.
  • The nozzle is clogged or partially blocked by dirt, dust, or debris, reducing the flow of filament.
  • The nozzle temperature is too low, making the filament too viscous and hard to extrude.
  • The filament diameter is inconsistent or out of spec, causing variations in the extrusion rate and pressure.
  • The filament is tangled, kinked, or twisted, creating friction and resistance in the feed path.
  • The extruder tension is too high or too low, making the extruder gear either slip on the filament or crush it.

To fix the extruder gear clicking problem, you need to identify the root cause and address it accordingly. Here are some possible solutions:

  • Adjust the nozzle height and level the build plate, making sure there is enough gap between them for the filament to flow out smoothly.
  • Clean the nozzle and check for any clogs or blockages. You can use a needle or a wire to poke through the nozzle hole or perform a cold pull to remove any stuck material.
  • Increase the nozzle temperature slightly and see if it improves the extrusion. You can also try a different filament material or brand that has a lower melting point or better flow characteristics.
  • Measure the filament diameter with a caliper and make sure it is within the tolerance range of your printer. You can also adjust the extrusion multiplier in your slicer software to compensate for any variations in the filament diameter.
  • Check the filament spool and make sure it is not tangled, kinked, or twisted. You can also use a filament guide or a spool holder to reduce any friction or resistance in the feed path.
  • Adjust the extruder tension and make sure it is not too tight or too loose. You can use a screwdriver to turn the tension knob or spring on your extruder assembly. You want to find a balance where the extruder gear grips the filament firmly but not too hard.