The possibilities of 3D printing are enormous, with the help of three-dimensional technologies you can translate almost any idea into a real full-color three-dimensional model.
3D printer manufacturers promise that the printing process is simple, automated and the user only needs to load an image and press a button. However, in practice, everything turns out to be not as perfect as we would like. The result of printing can be a big surprise. Unfortunately, there are many problems and difficulties in the process of 3D printing.
Let’s try to look at the most common, frequently occurring problems and difficulties of 3D printing and how you can overcome them.
So, the problems most often faced by the owner of any FMD printer. FDM (Fused Deposition Modeling) is a technology of layer-by-layer prototyping of engineering-grade thermoplastic.
Problem 1 – The first layers of plastic do not stick to the platform
The first layers of plastic do not stick to the platform, but are instantly pulled off the platform and rolled onto the extruder nozzle.
Reasons:
- large distance between the platform and the extruder nozzle;
- insufficiently heated platform.
The plastic sticks to the platform when the droplet coming out of the nozzle is distributed on the platform under pressure. For example: you are printing an object with a layer thickness (accuracy) of 100 microns. In this case the ideal distance between the nozzle and the platform will be – 50-80 microns, in this case the drop is distributed on the platform and sticks to it. The temperature of the platform should be 60-120 degrees, in the case of printing ABS plastic, it is a guarantee that the first layers will always remain in a semi-liquid state, thereby increasing the tenacity of the part with the platform. When printing PLA plastic, the platform is not heated.
Ways to fix the problem:
- turn the platform calibration bolts 30 degrees counterclockwise. If this does not save the situation, it is necessary to start the platform level calibration procedure again. It is very difficult to set the gap of 50 microns by eye, besides the platform changes its shape and deforms over time, complicating the calibration process even more;
- raise the temperature of the platform;
- be sure to adhere blue tape to the platform. Blue tape will allow the platform to be used at low temperatures or without heat, improve the quality of the object adhesion, protect the platform from damage, and allow you to separate the object from the platform without damaging the model.
How could the 3D printer manufacturer have prevented this problem?
It is necessary that the 3D printer platform calibration system is automatic, for example, as in welding machines designed for fiber optics.
Problem 2 – Loss of shape and melting of plastic parts
Reasons:
the use of poor quality plastic;- printing at high temperature differences between nozzle and platform.
Hot air flows are trapped between the extruder and the platform, and as a result, the finished plastic model (part) is exposed to hot air vapor, which causes the created part to melt.
Ways to fix the problem:
- reduce the platform temperature when printing with ABS plastic;
- increase the printing speed so that hot air does not accumulate in one place;
- use high quality PLA plastic with low heating temperatures (180 degrees for 40 degrees platform).
How could the 3D printer manufacturer have prevented this problem?
If you install a narrow-directional fan under the 3D printer extruder in front of the part, this problem can be easily avoided. The main thing is that the fan should only turn on when 5-10 layers are applied. This solution is already used in industrial 3D printers and Ultimaker 3D printers.
Problem 3 – ABS and PLA plastic peeling off the platform during printing (corners of the part are bent)
The main cause of ABS plastic peeling is the high cooling rate of the material.
These are the properties of ABS plastic and other high melting point plastics. It is for this reason that Makerbot has decided not to print with ABS and has opted for PLA. The edges of oblong objects made of PLA plastic can also scuff, in which case it is necessary to print with a substrate (RAFTS) or to increase the adhesion of the platform using tape or porous film.
Ways to fix the problem (relevant for both ABS and PLS plastic):
- to print in a high-temperature environment;
- avoid drafts and temperature changes;
- Use a special temperature control case for your 3D printer.
How could the 3D printer manufacturer have prevented this problem?
It is necessary for the 3D printer to be enclosed in order to thermostat the printing area.
Problem 4 – Plastic stops unwinding and feeding from the bobbin, plastic tangles up
Reasons:
bobbin shift;- poor quality plastic winding;
- the appearance of a node.
Makerbot, in an effort to save on consumables, has simplified the bobbin design so that feeding problems are simply unavoidable.
Ways to fix the problem:
- neatly installing the reel;
- check the winding for knots, and if the bobbin is jammed, correct it carefully;
- position the feed tube as close to the center of the bobbin as possible;
- use an external bracket for unwinding plastic with quality bearing construction.
How could the 3D printer manufacturer have prevented this problem?
Improvement of the unwinding process. In addition, it is necessary to improve the design of the reel itself. For example, 3D systems produce their own special cartridges for 3D plastic.
Problem 5 – Plastic Feed Stops
Reasons:
- imperfections in the clamping mechanism;
- small gap between the platform and the nozzle (plastic has no way to exit the nozzle and burns inside);
- nozzle clogging.
During the printing process, there are often times when the plastic cannot pass through the nozzle. In such cases, the extruder must independently increase the clamping force to compensate for the increased load.
Ways to fix the problem:
- Wet the bar with oil before starting the printing process;
- change the clamping mechanism;
- at the moment of stopping the plastic feed, increase the feed manually;
- Increase the gap between the extruder and the nozzle;
- raise the temperature of the plastic;
- change or clean the nozzle.
How could the 3D printer manufacturer have prevented this problem?
Using a fourth-generation clamping mechanism in 3D printers like WonWall does in their MigceCuble 3D printers
Printing on a monochrome printer can be a simple process if you remember the 5 rules of 3D printing above and try to avoid common mistakes. If it is still difficult for you and there are numerous problems in the printing process, do not hurry to get upset, contact 3D printing experts. Branding agency KOLORO will help you quickly, qualitatively and inexpensively create a 3D model of an object or part, as well as print it on a 3D printer.
