Revision as of 09:02, 20 November 2015

This guide is a great place to start if you are trying to improve the quality of your 3D printed parts. We have compiled an extensive list of the most common 3D printing issues along with the software settings that you can use to solve them. Best of all, the guide uses a large collection of real-world images to make each issue easy to identify when examining your own 3D printed parts. So let’s get started!

Not Extruding at Start of Print

This issue is a very common one for new 3D printer owners, but thankfully, it is also very easy to resolve! If your extruder is not extruding plastic at the beginning of your print, there are four possible causes. We will walk through each one below and explain what settings can be used to solve the problem.

Troubleshooting

1.Extruder was not primed before beginning the print

Most extruders have a bad habit of leaking plastic when they are sitting idle at a high temperature. The hot plastic inside the nozzle tends to ooze out of the tip, which creates a void inside the nozzle where the plastic has drained out. This idle oozing can occur at the beginning of a print when you are first preheating your extruder, and also at the end of the print while the extruder is slowly cooling. If your extruder has lost some plastic due to oozing, the next time you try to extrude, it is likely that it will take a few seconds before plastic starts to come out of the nozzle again. If you are trying to start a print after you nozzle has been oozing, you may notice the same delayed extrusion. To solve this issue, make sure that you prime your extruder right before beginning a print so that the nozzle is full of plastic and ready to extrude. A common way to do this in Simplify3D is by including something called a skirt. The skirt will draw a circle around your part, and in the process, it will prime the extruder with plastic. If you need extra priming, you can increase the number of skirt outlines on the Additions tab in Simplify3D. Some users may also prefer to manually extrude filament from their printer using the Jog Controls in Simplify3D’s Machine Control Panel prior to beginning the print.

2. Nozzle starts too close to the bed

If the nozzle is too close to the build table surface, there will not be enough room for plastic to come out of the extruder. The hole in the top of the nozzle is essentially blocked so that no plastic can escape. An easy way to recognize this issue is if the print does not extrude plastic for the first layer or two, but begins to extrude normally around the 3rd or 4th layers as the bed continues to lower along the Z-axis. To solve this problem, you can use the very handy G-Code offsets which can be found on the G-Code tab of Simplify3D’s process settings. This allows you to make very fine adjustments to the Z-axis position without needing to change the hardware. For example, if you enter a value of 0.05mm for the Z-axis G-Code offset, this will move the nozzle 0.05mm further away from the print bed. Keep increasing this value by small increments until there is enough room between the nozzle and the build platform for the plastic to escape.

3. The filament has stripped against the drive gear

Most 3D printers use a small gear to push the filament back and forth. The teeth on this gear bite into the filament and allow it to accurately control the position of the filament. However, if you notice lots of plastic shavings or it looks like there is a section missing from your filament, then it’s possible that the drive gear has removed too much plastic. Once this happens, the drive gear won’t have anything left to grab onto when it tries to move the filament back and forth. Please see the Grinding Filament section for instructions on how to fix this issue.

4.The extruder is clogged

If none of the above suggestions are able to resolve the issue, then it is likely that your extruder is clogged. This can happen if foreign debris is trapped inside the nozzle, when hot plastic sits inside the extruder too long, or if the thermal cooling for the extruder is not sufficient and the filament begins to soften outside of the desired melt zone. Fixing a clogged extruder may require disassembling the extruder, so please contact your printer manufacturer before you proceed. We have had great success using the “E” string on a guitar to unclog extruders by feeding it into the nozzle tip, however, your manufacturer should also be able to provide recommendations.

Print Not Sticking to the Bed

It is very important that the first layer of your print is strongly connected to the printer’s build platform so that the remainder of your part can be built on this foundation. If the first layer is not sticking to the build platform, it will create problems later on. There are many different ways to cope with these first layer adhesion problems, so we will examine several typical causes below and explain how to address each one.

Troubleshooting

1. Build platform is not level

Many printers include an adjustable bed with several screws or knobs that control the position of the bed. If your printer has an adjustable bed and you’re having trouble getting your first layer to stick to the bed, the first thing you will want to verify is that your printer’s bed is flat and level. If the bed is not level, one side of your bed may be too close to the nozzle, while the other side is too far away. Achieving a perfect first layer requires a level print bed. Simplify3D already includes a useful bed leveling wizard that you guide you through the bed leveling process. You can find this wizard by going to Tools > Bed Leveling Wizard, and following the on-screen instructions.

2.Nozzle starts too far away from the bed Once your bed has been properly leveled, you still need to make sure that the nozzle is starting at the correct height relative to the build platform. Your goal is to locate your extruder the perfect distance away from the build plate — not too far and not too close. For good adhesion to the build plate, you want your filament to be slightly ìsquishedî against the build plate. While you can adjust these settings by modifying the hardware, it is typically much easier (and much more precise!) to make these changes from the Simplify3D. To do this, click “Edit Process Settings” to open your process settings and then go to the G-Code tab. You can use the Z-Axis global G-Code Offset to make very fine adjustments to your nozzle position. For example, if you enter -0.05mm for the Z-axis G-Code offset, the nozzle will begin printing 0.05mm closer to your build platform. Be careful to only make small adjustments to this setting. Each layer of your part is usually only around 0.2mm thick, so a small adjustment goes a long way!

3.First layer is printing too fast As you extrude the first layer of plastic on top of the build platform, you want to make sure that plastic can properly bond to the surface before starting the next layer. If you print the first layer too fast, the plastic may not have time to bond to the build platform. For this reason, it is typically very useful to print the first layer at a slower speed so that the plastic has time to bond to the bed. Simplify3D provides a setting for this exact feature. If you click on “Edit Process Settings” and go to the Layer tab, you will see a setting labeled “First Layer Speed”. For example, if you set a first layer speed of 50%, it means that your first layer will print 50% slower than the rest of your part. If you feel that your printer is moving too fast on the first layer, try reducing this setting.

4.Temperature or cooling settings Plastic tends to shrink as it cools from a warm temperature to a cool temperature. To provide a useful example, imagine a 100mm wide part that is being printed with ABS plastic. If the extruder was printing this plastic at 230 degrees Celsius, but it was being deposited onto a cold build platform, it is likely that the plastic would quickly cool down after leaving the hot nozzle. Some printers also include cooling fans that speed up this cooling process when they are being used. If this ABS part cooled down to a room temperature of 30C, the 100mm wide part would shrink by almost 1.5mm! Unfortunately, the build platform on your printer is not going to shrink this much, since it is typically kept at a fairly constant temperature. Because of this fact, the plastic will tend to separate from the build platform as it cools. This is an important fact to keep in mind as you print your first layer. If you notice that the layer seems to stick initially, but later separates from the print bed as it cools, it is possible that your temperature and cooling settings are to blame.

Many printers that are intended to print high-temperature materials like ABS include a heated bed to help combat these problems. If the bed it heated to maintain a temperature of 110C for the entire print, it will keep the first layer warm so that it does not shrink. So if your printer has a heated bed, you may want to try heating the bed to prevent the first layer from cooling. As a general starting point, PLA tends to adhere well to a bed that is heated to 60-70C, while ABS generally works better if the bed is heated to 100-120C. You can adjust these settings in Simplify3D by clicking on “Edit Process Settings” and then selecting the Temperature tab. Choose your heated build platform from the list on the left-hand side and then edit the temperature setpoint for the first layer. You can just double-click on the value to change it.

If your printer has a cooling fan, you may also want to try disabling that cooling fan for the first few layers of your printer so that the initial layers do not cool down too quickly. You can do this by clicking “Edit Process Settings” and going to the Cooling tab. You can adjust the fan speed setpoints on the left-hand side. For example, you may want the first layer to start with the fan disabled and then turn on the fan to full power once you reach the 5th layer. In that case, you will need to add two setpoints into that list: Layer 1 at 0% fan speed, and Layer 5 at 100% fan speed. If you are using ABS plastic, it is common to disable the cooling fan for the entire print, so entering a single setpoint would suffice (Layer 1 at 0% fan speed). If you are working in a breezy environment, you may also want to try to insulate your printer to keep the wind away from your part.

5.The build platform surface (tape, glues, and materials) Different plastics tend to adhere better to different materials. For this reason, many printers include a special build platform material that is optimized for their materials. For example, several printers use a BuildTak sheet on the top of their bed that tends to stick very well to PLA. Other manufacturers opt for a heat treated glass bed such as Borosilicate glass, which tends to work very well for ABS when heated. If you are going to print directly onto these surfaces, it is always a good idea to make sure that your build platform is free of dust, grease, or oils before starting the print. Cleaning your print bed with some water or isopropyl rubbing alcohol can make a big difference. If your printer does not include a special build platform material to help with adhesion, you still have options! Thankfully, there are several types of tape that stick well to common 3D printing materials. Strips of tape can be applied to the build platform surface and easily removed or replaced if you want to print with a different material. For example, PLA tends to stick well to blue painter’s tape while ABS tends to stick better to Kapton tape (otherwise known as Polyimide film). Many users have also had great success using a temporary glue or spray on the top of their build platforms. Hair spray, glue sticks, and other sticky substances tend to work very well if everything else has failed. Feel free to experiment to see what works best for you!

6.When all else fails: Brims and Rafts Sometimes you are printing a very small part that simply does not have enough surface area to stick to the build platform surface. Simplify3D includes several options that can help increase this surface area to provide a larger surface to stick to the print bed. One of these options is called a “brim.” The brim adds extra rings around the exterior of your part, similar to how a brim of a hat increases the circumference of the hat. This option can be enabled by going to the “Additions” tab end enabling the “Use Skirt/Brim” option. Simplify3D also allows users to add a raft under their part, which can also be used to provide a larger surface for bed adhesion. If you are interested in these options, please take a look at our Rafts, Skirts, and Brims tutorial which explains things in greater detail.

Not Extruding Enough Plastic

Each profile in Simplify3D includes settings that are used to determine how much plastic the 3D printer should extruder. However, because the 3D printer does not provide any feedback about how much plastic actually leaves the nozzle, it’s possible that there may be less plastic exiting the nozzle than what the software expects (otherwise known as under-extrusion). If this happens, you may start to notice gaps between adjacent extrusions of each layer. The most reliable way to test whether or not your printer is extruding enough plastic is to print a simple 20mm tall cube with at least 3 perimeter outlines. At the top of the cube, check to see if the 3 perimeters are strongly bonded together or not. If there are gaps between the 3 perimeters, then you are under-extruding. If the 3 perimeters are touching and do not have any gaps, then you are likely encountering a different issue. If you determine that you are under-extruding, there are several possible causes for this, which we have summarized below.

Troubleshooting

1. Incorrect filament diameter The first thing you want to verify is that the software knows the filament diameter that you are using. You can find this setting by clicking “Edit Process Settings” and going to the Other tab. Check to make sure that this value matches the filament that you purchased. You may even want to measure your filament yourself using a pair of calipers to make sure that you truly have the correct diameter specified in the software. The most common values for the filament diameter are 1.75mm and 2.85mm. Many spools of plastic also include the correct diameter on the packaging.

2.Increase the extrusion multiplier If your filament diameter is correct, but you are still seeing under-extrusion issues, then you need to adjust your extrusion multiplier. This is a very useful setting in Simplify3D that allows you to easily modify the amount of plastic that is extruded (otherwise known as the flow rate). You can find this setting by clicking “Edit Process Settings” and going to the Extruder tab. Each extruder on your printer can have a unique extrusion multiplier, so if you are trying to modify the flow rate for a specific extruder, make sure to select it from the list on the left to load the settings for that extruder. As an example, if your extrusion multiplier was 1.0 previously and you change it to 1.05, it means you will be extruding 5% more plastic than you were previously. It is typical for PLA to print with an extrusion multiplier near 0.9, while ABS tends to have extrusion multipliers closer to 1.0. Try increasing your extrusion multiplier by 5%, and then reprint the test cube to see if you still have gaps between your perimeters.

Extruding Too Much Plastic

The software is constantly working together with your printer to make sure that your nozzle is extruding the correct amount of plastic. This precise extrusion is an important factor in achieving good print quality. However, most 3D printers have no way of monitoring how much plastic is actually extruded. If your extrusion settings are not configured properly, the printer may extruder more plastic than the software expects. This over-extrusion will result in excess plastic that can ruin the outer dimensions of your part. To resolve this issue, there are only a few settings you need to verify in Simplify3D. Please see the Not Extruding Enough Plastic section for a more detailed description. While those instructions are for under-extrusion, you will adjust the same settings for over-extrusion, just in the opposite direction. For example, if increasing the extrusion multiplier helps with under-extrusion, then you should decrease the extrusion multiplier for over-extrusion issues.

Holes and Gaps in the Top Layers

To save plastic, most 3D printed parts are created to have a solid shell that surrounds a porous, partially hollow interior. For example, the interior of the part may use a 30% infill percentage, which means that only 30% of the interior is solid plastic, while the rest is air. While the interior of the part may be partially hollow, we want the exterior to remain solid. To do this, Simplify3D allows you to specify how many solid layers you want on the top and bottom of your part. For example, if you were printing a simple cube with 5 top and bottom solid layers, the software would print 5 completely solid layers at the top and bottom of the print, but everything else in the middle would be printed as a partially hollow layer. This technique can save a tremendous amount of plastic and time, while still creating very strong parts thanks to Simplify3D’s great infill options. However, depending on what settings you are using, you may notice that the top solid layers of your print are not completely solid. You may see gaps or holes between the extrusions that make up these solid layers. If you have encountered this issue, here are several simple settings that you can adjust to fix it.

Troubleshooting

1.Not enough top solid layers The first setting to adjust is the number of top solid layers that are used. When you try to print a 100% solid layer on top of your partially hollow infill, the solid layer has to span across the hollow air pockets of your infill. When this happens, the extrusions for the solid layer have a tendency to droop or sag down into the air pocket. Because of this, you generally want to print several solid layers at the top of your print to ensure a nice flat, completely solid surface. As a good rule of thumb, you want the solid section at the top of your print to be at least 0.5mm thick. So if you are using a 0.25mm layer height, you would need at least 2 top solid layers. If you are printing at a lower layer height such as 0.1mm, you may need 5 solid layers at the top of your print to achieve the same effect. If you are noticing gaps between the extrusions in your top surface, the first thing you should try is increasing the number of top solid layers. For example, if you noticed the problem using only 3 top solid layers, try printing with 5 top solid layers to see if the problem is improved. Note that additional solid layers will occur within your part dimension and do not add size to the exterior of your part. You can adjust the solid layer settings by clicking “Edit Process Settings” and selecting the Layer tab.

2.Infill percentage is too low The infill on the inside of your part will act as the foundation for the layers above it. The solid layers a the top of your part will need to print on top of this foundation. If you infill percentage is very low, there will be large air gaps in your infill. For example, if you using an infill percentage of only 10%, the remaining 90% of the interior of your part would be hollow, and this would create some very large air gaps that the solid layers would need to print on top of. If you have tried increasing the number of top solid layers and you are still seeings gaps in the top of your print, you may want to try increasing your infill percentage to see if the gaps go away. For example, if your infill percentage was previously 30%, try using a 50% infill percentage, as this would provide a much better foundation for the solid layers at the top of your print.

3.Under-Extrusion If you have tried increasing the infill percentage and the number of top solid layers, yet you are still seeing gaps in the tops of your print, then you likely have an under-extrusion issue. This means that your nozzle is not extruding as much plastic as the software expects. For a full description of this issue and how to correct it, please read the Not Extruding Enough Plastic section.

Holes and Gaps in the Top Layers