3D printing is a precise and accurate additive manufacturing process suitable for producing products with complex designs. However, many users, especially novices, often face various shortcomings. One of the most common 3D printing errors is 3D printing deformation.
Deformation during 3D printing can have many causes and is frustrating for many people. For this reason, this article explains deformations in 3D printing, their causes, possible solutions and how to avoid deformations in 3D printing.
Concept of deformation in 3D printing
Warping is the deviation of a part from its intended shape.
To understand deformation in 3D printing, it is necessary to understand the 3D printing process and its relationship to the 3D printing filament. 3D printing involves extruding liquid filament from a heated nozzle into a (usually) heated printing bed. When it touches the print bed, the liquid condenses into its solid form.
3D printing filaments maintain their mechanical properties during phase transitions. However, they are subject to expansion and contraction (the degree of this physical effect depends on the filament). Temperature changes during the expansion and contraction of 3D printing filaments create a difference in expansion. If the extruded filament cools abruptly during shrinkage, it may cause the previous layer to tear off. This can lead to distorted 3D prints.
Deformation occurs in 3D printing as follows:
– Deformed 3D prints are most visible on the base layer, as it is exposed to large temperature fluctuations due to subsequent layers.
– Deformation can also occur with other layers, as subsequent layers have a pull-up effect when cooling the cold layers.
-A strong base coat can also cause deformation when adhering to the print bed.
There are other ways that warping can appear in 3D printing. They are explained in detail in the following section.
What causes deformation during 3D printing?
The main cause of deformation in 3D printing is the temperature difference during filament extrusion. However, there are also other causes. Below are some common causes to watch out for during 3D printing.
1. Temperature difference
During extrusion, the heated filament undergoes expansion and retraction. Temperature differences can lengthen or shorten expansion. If the extruded filament cools abruptly, it may result in a distorted 3D print.
This is the most common reason for warping in 3D printing and occurs due to uneven cooling, insufficient ventilation, insufficient fan speed, and incorrect choice of 3D printing filament.
2. Inadequate adherence to the bed
The first layer of 3D printing must adhere properly to the printing base. If this does not happen, the subsequent layer may shrink and pull on the first layer. This, in turn, can lead to a distorted 3D print. Insufficient adherence to bed may have the following causes:
- Incorrect bed leveling
- Incorrect use/lack of adhesive
- Incorrect nozzle height
- Insufficient extrusion
- A dirty 3D printing bed
3. Incorrect slicing settings
The slicer determines the 3D printing path, which is calculated from the object orientation, material and desired resolution. Therefore, incorrect slicer settings can lead to part errors. This can lead to construction panels detaching and deformation of the 3D print.
4. Very fast printing
Printing too fast can result in the following, which can result in distorted 3D prints:
- Plastic filaments curl instead of lying flat.
- Rapid printing may also cause the layer to cool abruptly. It also causes the plastic layer to become brittle.
How do you fix distorted 3D prints?
Repairing a distorted 3D print is nearly impossible, especially for products that require high levels of accuracy, precision and tolerance. However, for products that don't require as much tolerance, the only solution for a deformed 3D printed part is to reheat the part using a heat gun and shape it.
The most commonly considered solution to warping in 3D printing is to reprint the model. However, this should only be done after following the tips highlighted below.
10 tips to avoid deformation during 3D printing
Since it's nearly impossible to repair a distorted 3D print, you need to know how to avoid the problem before you print. Furthermore, this can also increase the cost of the 3D printing service. Below are some tips you can consider before and during high-quality 3D printing.
1. Level the print bed
By leveling the print bed, you can achieve the ideal distance between the nozzle and the print bed. For one, a closed nozzle can cause scratches on the bed (it does not cause deformation). On the other hand, a distant nozzle can cause the extruded filament to cool before it solidifies on the print bed. This reduces the adhesion of the extruded filament and causes deformation. You can level the print bed by performing a paper test or pressure test.
2. Heat the print bed and print head to a higher temperature for the first few layers
Heating the print bed and print head allows the extruded filament to have greater viscosity and adhere better to the print bed. For the first layer, be sure to increase the printing temperature by approximately 5°C. However, remember that this depends on the material you are working with.
3. Use a heated cabinet
A heated jacket ensures that the remaining part of the 3D print does not deform. This is achieved by keeping the temperature stable and reducing shrinkage.
Not all printers have a heated box. However, it is possible to build it yourself.
4. Use a raft and edge
Raft and Brim are also additional elements that prevent deformation during 3D printing. A raft is an additional layer firmly attached to the base layer. This keeps the layer in place and improves adhesion to the print bed. A flap is attached to the outer edge and has the same function of improving grip.
5. Configure slicing settings
You can also configure cropping settings to avoid warping during 3D printing. There are two settings you can use. One of them is to increase the height of the first layer by increasing the contact area. This increases accountability on the platform.
Another option is to extend the line width of the first layer. This increases extrusion pressure, improves adhesion and reduces the likelihood of curling. Make sure the setting does not affect wall thickness and other parameters.
6. Reduce fill density in 3D models
Fill density is the amount of filament in the model. Increasing the filling density will cause strong contraction during cooling, resulting in deformation.
Reducing fill density reduces the shrink rate, thus reducing the number of distorted 3D prints.
7. Reduce printing speed
Reducing printing speed can prevent warping, reducing curvature in 3D printing. Furthermore, by reducing the printing speed, cooling is facilitated, adequate adhesion occurs and internal tension is reduced.
8. Turn off the fan for the first few shifts
Cooling fans speed up the cooling process. At high speeds, they can abruptly cool the extruded filament as it shrinks, pulling the material upward. It can also lead to insufficient adhesion of the first layers to the print base. This leads to distorted 3D prints. Therefore, it is recommended to turn off the cooling fan and keep the first layer warm.
9. Clean the print bed
Cleaning the print bed can also help reduce the risk of warping. Because dust and dirt can reduce the adhesion of the filament to the printing base.
10. Use stickers
Use stickers, blue tape, or other adhesive products to improve the adhesion of the filament to the print base. However, make sure the adhesive does not affect the filament and is compatible with the print bed.
Differences between ABS warping and PLA warping in 3D printing
Deformation in 3D printing depends on the properties of the 3D printing filament. Therefore, there is a difference between the deformation of ABS and PLA. To understand the difference between the two materials, it is necessary to know their properties.
PLA is a thermoplastic with greater strength, rigidity and low melting temperature. However, it has a low melting temperature and is subject to deformation during 3D printing. Furthermore, after the filament hardens, it becomes brittle, which reduces the adhesion of the layers to the print base.
ABS is weaker, lighter and less rigid than PLA. Therefore, it requires more printing effort as it is heat resistant and prone to deformation. Therefore, when printing on ABS, use a heated print bed and a nozzle that is around 40-50 degrees Celsius.
Overall, the main difference between them is that ABS is more prone to warping than PLA. This is because PLA tends to curl if the print bed temperature is too low or the nozzle temperature is too high, but overall it warps less than ABS.
What other shortcomings are there in 3D printing?
Warping in 3D printing is not the only 3D printing defect that can occur. Below are some common mistakes in the process:
1. Ghosts
Ghosting is the appearance of small repeated lines on the surface of the model. It occurs by creating vibrations when the extruder changes direction. You can solve the problem by reducing the printing speed and checking the mechanical components of the printer.
2. Elephant's foot
This is the extent of the first layers of the 3D model in the horizontal plane. This occurs when the nozzle is close to the print bed or the print bed temperature is high. You can prevent elephant's foot by lowering the temperature of your bedding.
3. Overheating/frizz
This happens because the filament is heated and extruded at a very high temperature. Therefore the filament has less time to cool down. Therefore, it collapses or gives way. To avoid curling, lower the temperature and increase the fan speed.
4. Strings
Stringing occurs when plastic runs off one section of the print and sticks to another section as the nozzle moves. The problem arises from inaccurate settings. You can prevent stringing by lowering the temperature and increasing the printer's retraction speed.
5. Cracks
This occurs when the layers are not joined together correctly. This is due to poor adhesion between layers or thermal contraction.
To prevent cracking, increase the temperature and reduce the fan speed. You can also ensure that there is adequate cooling during printing.
University Degree
Deformation in 3D printing is a common phenomenon. They arise mainly due to temperature differences, which lead to deviations in cooling. Because they occur frequently, this process should be avoided. Therefore, we will talk about deformations in 3D printing, their causes and solutions, as well as how to avoid them.
Common questions
Can filament cause deformation?
Yes, using the wrong filament can cause deformation during 3D printing. For example, PLA and ABS are common filaments in 3D printing. However, due to its properties, ABS is more prone to deformation. To get the most out of 3D printing, make sure you understand the filament you're working with.
At what temperature does PLA deform?
PLA undergoes dimensional changes at around 70 °C. However, at a higher temperature (around 170°C) the object collapses (melts) completely.
Can wet filament cause warping?
Yes, wet filaments can become brittle during printing, reducing adhesion to the print bed. Additionally, wet filaments can cause bubbles that affect 3D printing quality.
