Problematic design

[Jody Harris]

I have run into an interesting problem. 

The design in the photo is one that I have printed before, but when I tried to printing it yesterday, it failed four times on two different printers. 

Filament: PCTG 

Printer 1: Prusa Core One 0.4mm nozzle

Printer 2: SeeMeCNC Boss Delta 300 0.6mm nozzle

Layer height: 0.2mm on both printers

I finally succeeded by printing it on the Core One at 0.25mm layer height. The previous successful prints were on the Boss Delta at 0.3mm layer height (PCTG).

I will make the model available for download if anyone wants to download and try it. (The design is my own.)

-j

Think carefully

[Kurt The 3D Printer GUY!!]

Sweet design sir - I would love to try printing it!

Can you give input on how you created - like what Software - and a tad about how you modeled it?

-K

[Bryan Eckert]

I'd like to see how my FLSun V400 does with it

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[Jody Harris]

Okay, do to "popular demand," (all two people), here's a link to a shared directory:

https://drive.proton.me/urls/FKVH157S44#VwRK9TQhxj24

Kurt, I designed it in OnShape. The technique I used was rather primitive. It also broke easily when I tried making changes in CAD. I got that "fixed," but I did find what I think is a better tool, so I hate to lead someone down a blind alley by explaining my method.

-j

Think carefully

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[Kurt The 3D Printer GUY!!]

Yo there Jody. Thanks for sharing - and for your feedback. Am printing it right now. Will keep you posted! Will DEF share a pic...

-K

[Kurt The 3D Printer GUY!!]

Honestly Jody - am not sure why you had several fails with printing this part. But, I suspect it failed part way up - since the side structures of the bowl are rather thin. 

It's funny - I thought it would be bigger - based upon your pic - and based upon dropping it into my slicer. Will also say - I printed this with ABS - which can be harder to print and is more prone to failure. Still - it came out GREAT:

Will admit - I did NOT notice all the stringing until seeing the pic on my PC here. I suspect people will say - Well DUH Kurt - your filament is Wet! And, I would not disagree - since the spool has been hanging on the side of my printer for Weeks now. But, I choose to keep that spool on to print with - considering the cool affect:

Ciao for now,

-K

[Jody Harris]

I suspect part of the problem is the physical characteristics of PCTG/PETG, but I have no experience with ABS. I'm sure it prints fine in PLA, too.

That came out really nice! Love the glow!

The really weird thing for me was four disasters at 0.2mm layer height, then a near perfect print at 0.25mm layer height.

-j

Think carefully

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[Kurt]

I think therein lies your answer. I feel that the thicker layer heights are more lenient in  regards to printing - and thinner layer heights tend to accentuate potential issues that can then cause a fail.

And, yeah - I actually printed at like 0.24mm layer heights. 

Glad you liked the print!

-K

[Bryan Eckert]

I plan to print it this weekend - at .08 layer height ;)

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[Jody Harris]

😬

Think carefully

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[Bryan Eckert]

Had zero luck on my V400 in PETG. Failed before it got to the first crossovers. 

My X1C is currently apart (installing X1Extender board), when I get it back together I’ll try it on that. 

[Kurt]

Bummer you had such bad luck on printing it. Am surprised - since it was Easy Peasy on my Elegoo - and I even printed in ABS. Will admit - I did a bit of a warmup of my printer - to try and get printer chamber heated up before I started printing.

-K

[Jody Harris]

I strongly suspect something in the design is sabotaging small layer lines. I just wish I could figure out what's causing it. It failed repeatedly at 0.2mm, but succeeded on my machines at 0.28mm (PCTG/Core One) and 0.3mm (PCTG/Boss Delta 300) and 0.24mm on the Elegoo with ABS.

-j

Think carefully

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[Anthony Rothert]

I'll give it a go as well.  I'm going to try it on 2 printers that have some random stuff loaded in it.  I don't have any PCTG.  There are no mods to either printer that affect print function and essentially basic/generic settings.

-  Bambu Lab A1 mini at .16 layer height with a .4 nozzle using generic, cheap silver PETG that has been sitting out for quite a while.

- FLSun V400 at .18 layer height with a .6 nozzle using generic, cheap gray TPU (~95A) that has also been sitting out for a while.  

[Anthony Rothert]

Honestly, I don't know if I have a use for this basket especially as a coffee filter drying basket, but I really like it and may print it again. I think the design is very satisfying to look at.  The way the petals (for lack of a better description) interweave is lovely.  

About 3 hours later, I have one and a half successes.

For reference I printed both of these with my preferred default, 3 walls, 3 top layers, 3 bottom layers, 10 % gyroid infill.

The A1 mini (.16 layer height, .4 nozzle) printed the model without hiccup.  There is minor stringing, but I ran straight generic PETG print settings.

The V400 (.18 layer height, .6 nozzle) uh... How do you feel about string theory?  It technically completed the print.  I can scrunch this thing repeatedly into a small ball and it rebounds without tearing layers.
However, it is EXTREMELY blobby.  In the closeup, I circled a few sections that have skewed layers.  I don't think its a layer shift, but that's the best way to describe it.  TPU is the trickiest filament
I currently have on hand.  If it was going to fail for me, that would have been it.  I don't want to call it a truly successful print, but it is a completed contiguous print.  
Note: as I type this, the close up picture from the V400 is only showing as an attachment.  Hopefully is viewable.

[Jody Harris]

Thanks for the complement on the design! "Petals." Perfect. Thank you. I've been struggling with what to call them.

I am surprised at your successes, but especially with the TPU print! I do believe that may be the stringiest print I've ever seen.

-j

Think carefully

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[Kurt The 3D Printer GUY!!]

Agreed - quite stringy - and String Theory is a good term here For Sure!!!

-K

[Anthony Rothert]

After thinking about the results, I think the TPU issues might be inherent to the material and design.  The petal arms are so small in diameter that as the layers stack up, the arms flex too much and cause shifting each time the nozzle lays filament down.That would explain the blobs.

[Kurt]

I will also add - TPU can be a pain to print. This is not the right design to print with it - all the travel moves are Bound to cause excessive stringing. That being said - it makes for a Funny pic!!!

-K

[Bryan Eckert]

My V400 is primarily my TPU printing machine, since it's a pain in the ass on the Bambu's since you can't use the AMS units. IT IS A TPU PRINTING BEAST! 

[Anthony Rothert]

I agree that the V400 does a great job withTPU.  I have a spool of Siraya Tech 85A.  The A1 Mini did a poor job of printing anything other than small single parts… not even sequentially printing the same small parts worked well using the 85A filament.  With 95 A, the A1 does great also.  I was amazed that the V400 handled the 85A great with very little setting changes.  I’m admittedly too lazy to put much effort into printer tuning for perfect prints.  I simply don’t have the time or patience. If I want high quality dimensionally accurate prints in anything but TPU, I just print on my A1 Mini or my new P1S.  If I want something in soft TPU or something big in PETG or PLA that doesn’t require tight dimensional accuracy, I use the V400.