1 Topic by dave.lantz (edited by dave.lantz 2015-01-07 18:42:34)

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Topic: Layer Adhesion and Sporadic Holes in Thin Walls

Happy New Year everyone! Finally back messing with my Solidoodle 4 after the hoildays.

Experienced a few issues with some designs I have done.

1) Bethlehem or Moravian Star - Created a multiple file design to build and glue together a sizable star. Base cube, four-sided spires and three sided spires all to be glued together to form the star.



      Problem 1 - when printing multiple copies (at once) of either spire which are thin walled pyramids either 3 or 4 sides; some of the pyramids on the outsides of the group end up with gaps in the wall and eventual failure of the spire. Some print fully and some have gaps.
      Problem 2 - thin walls have a tendency to break when handling along the layer lines. Too thin or lack of bonding layer to layer.
      Problem 3 - original base design was supposed to be hollow to allow lighting but this completely failed as the designed widened. Printing in space or on a widening edge? I see all types of "wire frame" models printed by 3D printers but for whatever reason my Solidoodle can't seem to handle it. I have attached the wire frame and the solid .stl files.

2) Task Lamp Mountable Base - created a two directional base for holding a task lamp that can be mounted on a wall or horizontal surface. To do this you need a hole in the Z axis and a hole 90 degrees to it on another face so it can be wall mounted. Anyway.... Slicer can't seem to handle blind intersecting holes. I ended up using Skeinforge but still got some error messages about holes and such in the model. It printed but I would like to understand why Slicer can't handle it and why Skeinforge is giving me errors. Its a pretty simple design!

I have attached files.

Thanks for any advice!

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2 Reply by OneMoreCast (edited by OneMoreCast 2015-01-07 19:22:15)

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

Whats temp of bed and hotend? Also what material

"All your base are belong to us." SD4 with a RUMBA, supernight PS, 40mm fan on X motor, lawsey carriages with new better tolerance rods, flanged rear bearings, new NEMA 17 with leadscrew on Z-Axis, and e3d v6 with MK5.


Ward and Jago are my heroes tongue

OneMoreCast's Website

3 Reply by dave.lantz

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

OneMoreCast wrote:

Whats temp of bed and hotend? Also what material

ABS filament
Hotend - 215°C
Table - 105°C

No problems with adhesion to the table and I print 8 spires at once. 5 were OK and 3 had holes as seen in the pics. The ones with holes were along the left rear edge of the array (as you are facing the printer).

Could it be a calibration problem or table alignment?

4 Reply by jagowilson (edited by jagowilson 2015-01-07 21:33:00)

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

Have you calibrated your extruder steps per mm (should be around 105, not 138)? Tell slic3r to output .48 extrusion (see advanced tab of slic3r), the solidoodle default of 0.42 is not correct for the 0.4mm nozzle on your machine. After you set the extrusion width properly calibrate your extrusion multiplier. There is a lot of info on all of these steps. If you Google, you should find Ian's blog. If you run into any problems, more than happy to help. Your prints don't look too bad, and I think this calibration should get you there if you haven't done it already.

Your pictures are a little blurry but I think your issues are simple over-extrusion. Newly extruded plastic bumping into already-extruded plastic causes all kinds of problems.

Running the latest version of slic3r and using netfabb's cloud repair service on your models is also important. I have never used Skeinforge myself so I can't help there. I didn't get a chance to look at your models myself but it's possible you may need supports enabled. Vertical holes are usually fine though.

5 Reply by dave.lantz (edited by dave.lantz 2015-01-08 03:47:46)

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

I will try the calibration and nozzle settings. I think you're right about the over-extrusion. I have seen it while printing.

I will also look for the latest version of Slicer and netfabb.

Are there instructions on how to update Slicer in the Repetier software?

Really appreciate your help!!! Thanks!

Any one have any ideas why the wire-frame star base won't print properly? As the model builds up and out, it starts to mess up after about 3/4" off the bed. The solid model came out nearly perfect but the wire-frame can't get past about 3/4" high.

6 Reply by OneMoreCast (edited by OneMoreCast 2015-01-08 09:01:22)

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

Did you print the wired one w supports...alot of these "ornaments and lighted" cutaway models are printed w supports and than removed after print. Im guessing the over hang on top is whats messing it up, along with settings possibly but after you get it sliced correct try adding supports

"All your base are belong to us." SD4 with a RUMBA, supernight PS, 40mm fan on X motor, lawsey carriages with new better tolerance rods, flanged rear bearings, new NEMA 17 with leadscrew on Z-Axis, and e3d v6 with MK5.


Ward and Jago are my heroes tongue

OneMoreCast's Website

7 Reply by jagowilson

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

dave.lantz wrote:

Are there instructions on how to update Slicer in the Repetier software?
.

In Slicer tab under Slic3r click the Setup button, and tell RH where slic3r.exe is in the Slic3r executable field (download the latest version from the slic3r website). Make sure Slic3r version is set to 0.9 or higher.

8 Reply by dave.lantz

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

OneMoreCast wrote:

Did you print the wired one w supports...alot of these "ornaments and lighted" cutaway models are printed w supports and than removed after print. Im guessing the over hang on top is whats messing it up, along with settings possibly but after you get it sliced correct try adding supports

I did not use supports. I'm not quite sure how to support it without adding a lot of material that would need to be removed later? Any suggestions?

BTW - I sincerely appreciate everyone's help!

Thank You!!!

9 Reply by dave.lantz

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

jagowilson wrote:

Have you calibrated your extruder steps per mm (should be around 105, not 138)? Tell slic3r to output .48 extrusion (see advanced tab of slic3r), the solidoodle default of 0.42 is not correct for the 0.4mm nozzle on your machine. After you set the extrusion width properly calibrate your extrusion multiplier. There is a lot of info on all of these steps. If you Google, you should find Ian's blog. If you run into any problems, more than happy to help. Your prints don't look too bad, and I think this calibration should get you there if you haven't done it already.

Your pictures are a little blurry but I think your issues are simple over-extrusion. Newly extruded plastic bumping into already-extruded plastic causes all kinds of problems.

Running the latest version of slic3r and using netfabb's cloud repair service on your models is also important. I have never used Skeinforge myself so I can't help there. I didn't get a chance to look at your models myself but it's possible you may need supports enabled. Vertical holes are usually fine though.

Not sure where you are referencing? Advance tab of Slic3r doesn't have this info in my configuration settings.

10 Reply by jagowilson (edited by jagowilson 2015-01-08 16:24:03)

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

dave.lantz wrote:

Not sure where you are referencing? Advance tab of Slic3r doesn't have this info in my configuration settings.

http://www.soliforum.com/misc.php?action=pun_attachment&item=7301&download=0

Note that the support material of 0.24 setting may or may not work for you. It works on my e3d with a 0.4mm nozzle, but not sure about the stock hotend. The other settings will work fine and will get you started. Feel free to experiment with them, though; I rarely leave them all the same and this is just an old profile.

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11 Reply by dave.lantz

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Re: Layer Adhesion and Sporadic Holes in Thin Walls

Thanks so much Jago! HUGE help! Going to try it the next few days. Thanks again!