2020 Edition

3D Printing Failures
How to Diagnose & Repair all Desktop 3D
Printing Issues
By: Sean Aranda
Edited by: David Feeney
Material Science by: Nicolas Tokotuu, Product
Manager at Polymaker
Special Thanks to:
All of my subscribers and Patrons
David Feeney and Bennett Berger
Nicolas Tokotuu of Polymaker
Timothy at TH3D
Hanna Henry for the cover design
©2020
 Table of Contents
Introduction
Diagram of a 3D Printer
Diagnosing Failures
Bed Adhesion
Build Plate Not Heating
Build Plate Not Reading Correct Temperature
Built Up Material in Nozzle
Electrical Safety
Elephant Foot
Extruder Stepper Skipping
Filament Snaps
Gaps in Walls
Ghosting
Hotend Can’t Reach or Maintain Temperature
Hotend Not Heating
Hotend Not Reading Correct Temperature
Important Accessories and Replacements
Layer Shifts
LCD Blank or Dark
Mandatory Maintenance for your 3D Printer
Material and their Settings
Material Science
Missing Layers
Model Errors
Not Finding Home and Inverted Prints
Nozzle Clogs
Over/Under Extrusion
Parts Being Knocked Over
Parts Not Mating Together
Poor Layer Adhesion
Post-Processing
Print Pauses Mid-Print
Quality Options
Running Out of Filament
Settings Issues
Speed Limitations
Stepper Motors Overheating or Malfunctioning
Stripped Filament
Unlevelled Build Plate
Warping:
Z- Axis Wobble
Z- Height Calibration
Tips if Still Not Working
Limitations Involved with 3D Printing
Upgrades and Purchasing a New Printer
Resources
About the Author
Introduction
When I first started working with 3D printers, I was overwhelmed by the
amount of knowledge required to have consecutive successful prints. Since
I was aware of the acceptable failure rate for most other manufacturing
machines, I was blown away by just how inconsistent 3D printing can be
without frequent, proper maintenance.
Many desktop 3D printing companies advertise a plug and play machine
that can be operated consistently without any engineering background,
which is generally not true. 3D printing has been marketed by many as a
magical solution to manufacturing and prototyping, but anyone who has
used these machines will be able to tell you different.
From the time I began in this industry roughly five years ago, up to the
point of writing this book, I have amassed well over 75,000 hours of
successful printing (machine run time) across over two dozen types of FDM
machines. I have repaired just about every section of the printer and have
even built my own. Since prints can fail up to 20% of the time without
proper maintenance, you can be safe to assume I have had to fix just about
every issue you will come across.
This 2020 edition of the book has been entirely re-written. Every single
chapter has been updated to any new information I have run into, including
the use of new software. I have also been reached out to by individuals who
have purchased the previous editions with their problems not covered in
their edition, which are now included in this. There are many new photos to
help diagnose and fix problems and there 6 entirely new chapters. One of
these chapters has been written by an industry leader, with the “Material
Science” chapter being written by Nicolas Tokotuu of Polymaker. All of
this information is to make sure everything is up to date.
There is also a chapter on electrical safety that was added and helped to
make by Timothy at TH3D, which I think 100% of you should read.
Preventing a fire should be your number 1 concern when getting into 3D
printing.
I suggest everyone read the chapter on material science before just about
anything else in this book. Understanding the “Material Science” chapter
helps explain the “why”. If you fully understand that chapter, it is likely that
you will be able to diagnose and fix many of your issues without
referencing the rest of this book.
I also suggest you check out the “Limitations Involved with 3D Printing”
chapter if you are new to 3D printing, since FDM machines are not a one-
stop solution for anything you need.
In the diagnostic section in the beginning of this book I will go over some
of the visual symptoms that you may see when your printer is
malfunctioning, and what could be causing the problem. Whatever failure
or ugly print you are experiencing, you should be able to compare it to the
problem described, and then go to the designated chapters in order to fix.
My goal with this book is to take every failure I have witnessed and put it
into one resource. This book should be able to help you fix close to 100% of
the problems you are going to experience with your 3D printer. If you
purchased this book and it does not help you with your specific problem, I
offer you to contact me anytime at my YouTube channel “The 3D Print
General”, or to email me at [email protected]. I also open you to
email me with proof of purchase for higher definition colored photos, since
the publishing process will often reduce the quality.
Warnings for using your 3D printer
Since I personally believe this industry does not do a proper job of warning
the dangers involved with 3D printing when advertising products to average
consumers, I feel it necessary to caution you of the real possibility of a fire
while operating one of these machines. This is equipment that draws a lot of
power, shakes and moves for hours, and has a lot of wires that can be
dislodged or frayed. Many inexpensive manufacturers do not take the
proper cautions. You shouldn’t run your printer next to curtains or other
flammable things, and you shouldn’t leave your machine printing alone for
hours if you are not confident in your build quality. I personally have an
AFO Fire Extinguishing Ball mounted above my printers as insurance
against the worst case scenario, and suggest everyone else to do the same.
EVERYONE should check out the video by Thomas Sanladerer titled
“Everything you need to know to make your 3D printer fireproof!” on
YouTube. There is some complicated things that he goes over, but it is
crucial that you understand this before you purchase a $200 printer with a
heated build plate and leave it unattended. There is a somewhat abridged
version of his video as a short chapter in this book titled “Electrical Safety”
that you should read over, which some of the basics are covered.
Another concern is that not much research has been done in relation to the
amount of harmful particulates put into the air from melting plastic in this
fashion. You can imagine that if you threw some Lego’s into an oven and
inhaled the smoke that was created, you would be doing some serious
damage to your health. You should make sure that your 3D printer is in a
well-ventilated area, and that you do not stand over the hotend watching it
while it prints. Some manufacturers have factored this issue into their build
design and enclose the machine, ventilated with filters. Specific materials
are worse for your health than others, but it is a good rule of thumb to
assume that melting plastic and inhaling it is not going to be good for your
lungs.
Notes about different types of printers
This book will only cover FDM desktop 3D printers and will not be able to
help fixing SLA machines, SLS machines, or any other form of 3D printing.
There may be some generic rules that overlap, but I was only factoring in
FDM 3D printing when writing this book.
What is FDM 3D Printing?
There are quite a few different forms of 3D printing available today, but the
most common used in homes around the world is known as Fused
Deposition Modeling (FDM). FDM printing works by laying down
consecutive layers of material at high temperatures – with each layer given
time to cool and bond together before the next layer is deposited.
This can actually be thought of as the inverse of computer numerical cutting
(CNC). 3D models are transformed into G-code via a slicing program,
which work as instructions for the 3D printer, telling it exactly where to
move next, and how much volume is required to extrude. This additive
process only uses the amount of material required to create the part, versus
CNC which is subtractive and requires excess material which it is then cut
from. The only exception to this is the support material required for
overhangs in FDM 3D printing, acting as a form of scaffolding that is
broken off after printing.
NOTE: I have done my best to have these photos show up in high quality,
but Amazon’s printing process does not seem to always be up to par. Email
me at Sean@3DPrintGeneral and I will be happy to send you the HD
version of these photos, along with a PDF version of this book - with proof
of purchase.
Pros to Using FDM Printing
First and foremost - the most beneficial reason to use FDM 3D printing is
the costs involved. FDM printers are very affordable when compared to
other printing methods, and the material can be drastically less expensive.
With the expansion of 3D printing over the last few years, the amount of
material options have increased rapidly. FDM printing now allows for
printing in flexible, nylon, and carbon fiber blends - some of which have
strength that would surprise the average individual. There are likely over
one hundred types of materials now available, each with their own price,
strength, heat resistance, flexibility, and ease to print – meaning there is
something available for almost any application. This material option is a lot
less expansive when working with other forms of 3D printing.
Types of FDM 3D Printing

Many of the axes and solutions I describe are for

Cartesian machines. A Cartesian FDM 3D printer is one in which the build
plate moves in the Y direction, the extruder moves in the X direction, and
the carriage is moved up and down in the Z direction. This is how most
desktop FDM 3D printers function. The photo is a digram of how most
Cartesian printers find “home”, though some home to their max.
A CoreXY machine is where the bed moves up and down in the Z direction,
and the extruder moves in both the X and Y direction. There are some
variations with this, such as an H-Bot, but they essentially work the same.
While I may call all of these printers “CoreXY” that is because they were
the first gantry system I was aware of, but I am actually referring to a gantry
system in general. There are definitely some benefits involved with this
method since you should be able to achieve some tighter tolerances, as well
as avoid some Z-wobble and thin parts being knocked over from the bed
rattling. Your frame should also be able to print much faster without
printing issues due to the lack of the heavy bed being moved back and forth.
Many prefer a CoreXY machine, including myself – they are just not as
common as Cartesians.
A Delta 3D printer looks and functions quite differently than either of these,
since the extruder is suspended above the build plate via three arms in a
triangular fashion. These machines have their downfalls but can normally
print much faster than a Cartesian with the same specs. I personally do not
have much experience with these types of FDM machines.
You should be able to use all of the remedies in this book on CoreXY and
Delta machines, but some of the dimensions described in the directions and
firmware will be different.
There are also two types of extruder setups – direct and Bowden – both of
which can have a gear ratio or not. A direct extruder is one where the
stepper motor is feeding filament directly into the hotend, and is attached to
the carriage. A Bowden option is where filament is fed from a stepper
motor attached to the frame to the hotend carriage. A Bowden extruder will
reduce the weight on your carriage which means you can normally print
much faster. The problem with Bowden machines is the difficulty involved
with printing unique materials and fine nozzles, with some very flexible
options and very fine nozzles being entirely impossible. You will also need
to ramp up the retraction settings in order to prevent a “hairy” print, which
is covered further in this book.
I do cover Bowden setups in this 2020 edition of the book, but in general I
am discussing using a direct extruder, since I prefer those.
Good Practice
Before I get into the specifics of fixing particular failures, I feel it necessary
to go over some good practices to maintain your printer in top condition.
Since 3D printers are mechanical machines that experience frequent rattling
and movement, they require constant maintenance in order to continue
performing at their peak. Look over the “Mandatory Maintenance” chapter
as well to make sure you properly take care of your printer.
Keep a clean environment
If you do not make sure to always clean up your printer work area, you will
be surprised just how quickly everything can get out of hand.
Make sure you always throw away excess material since it can eventually
get in the way of your gears turning properly. Since there are fans blowing
on different sections of your printer, you could even blow some stringy old
material onto your current print.
Keeping your printer clean includes your build plate. This does not need to
be cleaned after every print and will be determined by your specific build
plate and adhesion method (as described in the “Bed Adhesion” Chapter). I
like to clean off my build plate every couple of prints to make sure I have a
proper first layer.
If you have an air compressor it can help immensely with cleaning the
different parts of your printer from debris and dust.
Print replacement parts that are likely to
break in advanced
You really don’t want to wait for a printed part on your machine to break
and to not have a replacement on hand. If you only have one 3D printer, you
are going to have to order replacements, when it could have been as easy as
printing an extra set when you first got your machine.
The first thing I do when I get a new machine is I print a replacement set of
printed parts, the files for which are normally provided by the manufacturer.
If not, you can likely find them on Thingiverse. This is not much fun
because the first day or two of printing will just be these parts, and not
anything cool for yourself.
Keep these parts to the side and hope you will never need them, but you
will be happy you did this if you ever do. I have kicked myself plenty of
times in the past when I did not do this.
Slow your printer down
Many printing issues can be fixed or diagnosed easier if you run your
machine a bit slower. There are possibilities you can run into a nozzle clog
by doing this, but in general, you will have a much higher success rate by
printing a bit slower.
You can do this by reducing your print speed in your slicer settings and by
reducing your machine’s acceleration, both of which are described later in
this book.
I personally run my machines much slower than the manufacturer advertises
and what many makers say they print at.
Save slicer profiles as you go
Every time you make a tweak to your slicer settings, you should save it as a
new file, organized somewhere on your computer. This is a good practice so
that you can go back to profiles you know have worked in the past and can
save you an immense amount of time when printing a unique material you
know you have successfully printed in the past.
You can personalize profiles to specific machines and for each material you
are printing with. This is the best way to hone in and perfect your settings
for any given filament.
If you don’t do this, you can still load a profile from a G-code. You should
save your G-codes in a manner that can easily be remembered if the
particular slicer settings are needed in the future. Don’t just call your G-
codes “Print 5” in a generic folder, since you will not be able to easily recall
it later in the future.
Properly store your filament
Filament, especially nylon mixtures, can absorb and maintain moisture
when kept in a humid environment. This is why when you purchase a new
spool, the filament will always be vacuum sealed with desiccants.
If you do not plan on using your filament for some time, you should
properly store it with a dehumidifier or vacuum seal it. If you do not, you
may start to experience failures on a spool you have used successfully in the
past.
Almost all filament wants to be stored in as close to 0% humidity as
possible. I would set my dehumidifier to the lowest setting – 20% - which
always worked great. I used to live in a very dry area where humidity rarely
gets above 30%, so I did not have to deal with this nearly as much as
someone living in a very humid area of the world. Now that I have moved
to Texas I have to be much more careful in preserving my material.
Always watch the first layer of your print
before leaving unattended
This is a very important tip. Never start a print and just walk away before
watching that first layer print. Even with a $5,000 machine with auto
levelling, and a technician with a lot of experience, it would be inadvisable
to not watch this first layer print.
Any issue with finding the proper Z-height can lead to a failed print that can
damage your machine. If the print starts too close to the build plate, you
may have to kiss your build plate and nozzle goodbye. If the print starts too
far from the build plate, you are going to have a massive cleanup on your
hands.
I would guess that 75% of the failures I experience can be diagnosed from
the first layer. This is the fastest set of failures to diagnose, but if you don’t
watch the first layer printing, you will be left with quite a lot of headaches.
To this day I watch 100% of my prints first layer before leaving the
machine unattended.
Dedicate specific machines to particular
materials if possible
If you happen to be able to own a few printers, I suggest designated
particular machines (or at least hotends) to specific materials. If a machine
only prints PLA, it will run into less issues than the same printer that runs
many different materials. Switching materials can leave debris, different
printing and build plate temperatures can require Z-height calibration, and
different abrasive materials can cause the need for different types of
nozzles.
I understand this is not possible for those who only have 1 or 2 printers, just
keep in mind that every time you switch to a different type of material you
will have different tweaks you need to make.
Don’t get frustrated
3D printing can involve more annoyances than you may have first
imagined. It might take you 20 re-prints just to hone in the proper Z-height
and to level your build plate, if you are not used to the machine. Or you
may start a 28 hour print that decides to clog 26 hours in.
There are countless ways that 3D printing can end up leaving you
frustrated, but it is key to keep calm. Remember that there is a solution to
the problem you are having and you just need to properly diagnose it.
Diagram of a 3D Printer
** Reminder** All photos in this book, including the diagram below, may
have been printed in poor quality for your edition, which was out of my
control. If you would like high definition color photos, as well as a PDF
version, just email me at [email protected] with proof of purchase
and I will send them your way.

1. Z Carriage. This connects to both the Z rod and threaded rod/leadscrew.

The leadscrew then turns due to the stepper motor it is attached to, which
then moves the x carriage up and down. On Bowden machines this is often
where the extruder is attached.
2. X Endstop. This is what tells the hotend to stop when homing. There is
also a Y and Z endstop not shown in this picture which have the same
function (though a Z endstop may be replaced by an auto bed leveler).
3. Build plate. This can be either glass, PEI, or another form of build plate.
This is where the prints stick to.
4. Nozzle. Filament is fed through a heated nozzle in order to form your
print. These can be found with different diameter holes, with the smaller the
hole, the finer the detail. Nozzles range from 0.15mm – 1.4mm in diameter.
They also come in brass, hardened steel, and ruby tip, with each becoming
more abrasive resistant and more expensive.
5. X Carriage. This is where the hotend (and printers with direct extruders)
attach to. The X carriage is attached to the X rods and belt which then in
turn move the hotend in the X direction. This carriage should be very
secured and not have any rattling.
6. Extruder. This is how the filament is fed into the nozzle. In this example
I am showing a non-geared direct extruder. A geared extruder will have a
gear-ratio allowing for less stress to be placed on the stepper motor, also
adding a mechanical advantage for more torque, allowing the filament to be
fed faster. The extruder includes a tooth drive attached to the stepper motor
that pinches the filament against a bearing that freely spins. There are dual
drive extruders as well which replace this bearing with another tooth drive.
This extruder can also be placed on the Z carriage in a Bowden fashion.
7. Extruder Stepper Motor. The extruder stepper is what turns and feeds
filament through the extruder. This would be placed on the Z carriage when
on a Bowden setup. This is what you are controlling when you set the E-
Steps. When using a geared-extruder, you put less strain on this stepper
motor by giving it a mechanical advantage, which would result in less
extruder motor skips. It would be smart to place a heat sink on this in order
to disperse heat.
8. X Carriage Belt. This is what is connected to the X carriage as to move
it left and right in the X direction. This belt should be tight/springy to the
touch as to reduce Z-wobble.
9. Y Stepper Motor. This stepper motor moves the bed back and forth in
the Y direction by controlling the Y carriage belt. This is only present in
this fashion on Cartesian machines.
10. Y Carriage Belt. This is the belt that is connected to the build plate and
is controlled by the Y stepper motor and spins freely on a bearing on the
other side. Just as with the X carriage belt, this should be tight and springy
to the touch.
11. Y Smooth Rods. These rods are what the Y carriage are attached to via
bearings and are smooth to the touch. They help to make sure the build
plate moves smoothly back and forth without rattling. These rods should be
lubricated with white lithium grease so that the build plate can move
without resistance. These can be replaced with a rail system instead on
particular machines.
12. Active Cooling Fan. This fan is used to cool prints as layers are being
laid down. This is crucial to use to get clean prints with particular materials,
including PLA. This can lead to decreased layer adhesion on other
particular materials, so you need to confirm the material you are using
before turning it on in your slicer settings.
13. Z Stepper Motor. On some machines there is only one Z stepper motor,
but there are dual steppers in this example. This stepper motor turns the Z
leadscrew (or thin threaded rod) and moves the X and Z Carriage up and
down, via where it is connected to the Z carriage (1 in photo). This is
different on CoreXY machines, since those move the build plate up and
down instead of the hotend.
14. Heaterblock of Hotend. This is the part of the hotend that gets hot and
is attached to the heater. This is attached to the nozzle below it, and the
barrel above it (with a heatbreak in between). The barrel should always
have a fan blowing on it to prevent heat creep, though one is not shown in
this picture.
15. X Smooth Rods. These rods are what the X carriage holds onto via
bearings and are smooth to the touch. They help to make sure the hotend
move smoothly left and right without rattling. These rods should be
lubricated with white lithium grease so that the carriage can move without
resistance. These can be replaced with a rail system on particular machines.
16. Z Smooth Rods. These are what your Z carriage is attached to via
bearings in order to ensure the Z carriages are moved up and down
smoothly without rattling. They should remain lubricated just like the X and
Y smooth rods as to ensure there is as little friction with the bearings as
possible. These can also be replaced with a rail system on particular
machines.
17. Z Leadscrew (or threaded rod). These are threaded rods ranging from
5mm-10mm in diameter, with 8mm seeming to be the most common. Many
inexpensive machines only have one of these, but I have found when there
are dual leadscrews you get more consistent results. These are turned via
the Z stepper motors which then thread into the Z carriages – moving the Z
and X carriages up and down. These have essentially the same function for
the Z carriages as the belts have for the X and Y carriage. They are threaded
rods though because more weight is placed on these parts, and less frequent
moving is required out of the Z direction. In general, the thicker these
leadscrews are, the better. Thin 5mm threaded rods can become bent and do
not last long on 3D printers. This is what moves the build plate up and
down on CoreXY machines.
Diagnosing Failures
Don’t forget to email me at [email protected] with proof of
purchase for HD photos.
Nozzle Too Close To Buildplate

Check Chapters:
Z-Height Calibration
Unlevelled Build Plate
Nozzle Too Far From Buildplate

Check Chapters:
Z-Height Calibration
Unlevelled Build Plate
Uneven Build Surface

Check Chapters:
Unlevelled Build Plate
Spaghetti Monster

Check Chapters:
Z-Height Calibration
Unlevelled Build Plate
Built Up Material On Nozzle

Check Chapters:
Built Up Material On Nozzle
Nozzle Clogs

Check Chapters:
Nozzle Clogs
Settings Issues
Bed Adhesion for Above Issue
Ghost Printing

Check Chapters:
Nozzle Clogs
Stripped Filament
Settings Issues
Material and their Settings
Mandatory Maintenance
Filament Snaps

Check Chapters:
Filament Snaps
Settings Issues
Material and their Settings
Running Out Of Filament

Check Chapters:
Running Out Of Filament
Endstop Not Engaging

Check Chapters:
Not Finding Home
Error: MINTEMP

Check Chapters:
Hotend Not Reading Correct Temperature
Hotend Not Heating

Check Chapters:
Hotend Not Heating
Hotend Cannot Reach Set Temp

Check Chapters:
Hotend Cannot Reach or Maintain Temperature
Build Plate Not Heating

Check Chapters:
Build Plate Not Heating
Build Plate Not Reading Temp

Check Chapters:
Build Plate Not Reading Correct Temperature
LCD Screen Dark

Check Chapters:
LCD Blank or Dark
Black Spots on Print

Check Chapters:
Built up Material on Nozzle
Material and their Settings
“Wobbly” Print

Check Chapters:
Z- Axis Wobble
Single Layer Shift

Check Chapters:
Layer Shifts
Multiple Layer Shifts

Check Chapters:
Layer Shifts
Over Extrusion

Check Chapters:
Over and Under Extrusion
Under Extrusion

Check Chapters:
Over and Under Extrusion
Parts to Wrong Dimensions

Check Chapters:
Parts Not Mating Together
Parts Not Mating Together

Check Chapters:
Parts Not Mating Together
Over and Under Extrusion - Over Extrusion
Warping

Check Chapters:
Warping
Material Science
Bed Adhesion
Layer Delamination

Check Chapters:
Warping
Material Science
Over and Under Extrusion - Under Extrusion
Poor Layer Adhesion

Check Chapters:
Poor Layer Adhesion
Over and Under Extrusion - Under Extrusion
Settings Issues
Ugly Top of Print

Check Chapters:
Settings Issues - Lift Head Cooling
“Pitted” Top Side of Print

Check Chapters:
Settings Issues - Shell and Fill Settings
Ugly Underside of Print

Check Chapters:
Settings Issues - Support Settings
“Hairy” Prints

Check Chapters:
Settings Issues - Material Retraction
Material and their Settings
Material Science
Droopy/Ugly Undersides

Check Chapters:
Settings Issues - Support Settings
Text Not Legible

Check Chapters:
Parts Not Mating
Over and Under Extrusion - Over Extrusion
Quality Options
“Veiny” Print

Check Chapters:
Settings Issues - Infill Overlap
Ghosting
Ghosting

Check Chapters:
Ghosting
Stripped Filament

Check Chapters:
Stripped Filament
Elephant Foot

Check Chapters:
Elephant Foot
Gaps in Walls

Check Chapters:
Gaps in Walls
Missing Layers

Check Chapters:
Missing Layers
House on Fire

Check Chapters:
Electrical Safety
Bed Adhesion
Having proper bed adhesion is crucial to any successful print. Using
different materials, nozzle diameters, layer heights, and 3D models can lead
to the need for different slicer settings and manual calibration for proper
bed adhesion. While the issue may be frequent, it can normally be
diagnosed early on into the print. The few times you lose bed adhesion mid
print, it can lead to big issues, so make sure you take the proper precautions.
These tips are also crucial in avoiding any warping on your parts, as
mentioned in that chapter.
Understanding the material you are using
Not only does each material affect your bed adhesion and settings required,
each manufacturer can as well. I highly recommend against using low
quality filament brands since their tolerances, humidity, and reliability are
frequently subpar. I personally use Hatchbox, Overture, Polymaker, or AIO
Robotics for PLA, Fiberlogy and MatterHackers for PETG, 3DXTech and
MatterHackers for carbon fiber blends, taulman3D and Polymaker for
unique nylons, and NinjaTek for their various flexible materials. There are
many other reputable manufacturers as well, but I have found I like these
companies best out of the ones I have personally tested. Read reviews
before buying any material. Further information in this regard are included
in the “Material and their Settings” chapter, as well as the “Material
Science” chapter.
You may also be able to switch to a different material with similar
mechanical features but with better bed adhesion properties, as gone over
further in the “Warping” chapter.
Slow down the speed on your first layer
and turn off active cooling fan
Having your first layer extrude properly is needed to making sure that the
rest of the print follows suit. Even after 5 years of experience and using
higher end FDM machines, I will always watch the first layer to make sure
it prints properly. If you just decide to start a print and walk away, you can
come back to a very messy or warped print.
You will want to confirm that your first layer is running very slowly
compared to the rest of your print (30%-60% print speed or ~20-30mm/s),
and that no active cooling fan is on.
This makes sure that the first layer has its best chance of sticking to the bed,
which is the most difficult layer for adhesion on any material.

Have a heated build plate

If you want the best adhesion possible, you are going to need a heated build
plate. You may be able to get away with printing specific materials without
a heated build plate, but even PLA sticks better when the bed is heated to
around its glass transition temperature.
The glass transition temperature of a material is always lower than the
extrusion temperature and relates to when the material starts to become
viscous without actually going through a phase transition. When the
material becomes slightly viscous, it will be able to stick to the build plate
much easier. This may cause an “Elephant Foot” issue, so refer to that
chapter if experiencing this problem.
Below are the temperatures I set my heated build plate for various
materials. Please keep in mind you will need to have your board actively
cooled in order to have your bed reach and maintain some of these
temperatures, and always refer to your specific manufacturers
recommendations.
PLA: 50 - 60°C
ABS: 105°C
PETG: 50 - 80°C
CFR-ABS: 105°C
CFR-Nylon: 80°C
Cheetah by NinjaTek: 40°C
Ninjaflex: 50°C
PCTPE: 45°C on a glass bed with a coat of PVA
Nylon 910: 45°C on a glass bed with a coat of PVA
Polymaker PolyMide CoPA: 60°C
Polycarbonate ABS: 120°C bed (and can only print in an enclosed
machine)

Clean your bed before applying anything

Fingerprints and residue from previous prints on the plate can prevent the
first layer from sticking to the plate properly. Isopropyl alcohol is used to
properly clean uncoated glass and PEI beds, while acetone can be used on
glass (most PEI beds will be ruined with acetone, so be careful when using
that material). As mentioned below, when cleaning a PVA solution you
should only use soap and water, since that is what it is soluble in.
PEI beds require a clean surface in order to stick properly, and glass will
always perform better after being cleaned, so make sure you clean this plate
every 5-10 prints.
Having a proper initial Z-height
This is likely the most important step in getting a good first layer. The
initial Z-height refers to how far the nozzle is from the build plate. You can
easily imagine that if you start a print with your nozzle an inch off of the
build plate that the material will not stick.
This is also covered in the “Unlevelled Build Plate” chapter, but essentially
the distance from the nozzle to the build plate needs to be honed in based
off the initial layer height. A good starting point should have the nozzle
roughly the thickness of a piece of paper in distance from the build plate.
This means that you can home your printer and grab a piece of computer
paper. You should be able to slide the piece of paper under the nozzle with a
slight amount of drag. If you cannot slide the paper under the nozzle, it is
likely too close to the build plate, and if you get no resistance, the nozzle is
likely too high.
While this is a go-to method, it does need tweaking depending on your
initial layer height. I have actually gotten to the point where it is easiest for
me to visually determine the proper layer height. Below are a couple of
comparison photos, but essentially if the material is spreading out, the
nozzle is too close, and if there is a gap between layer lines, it is too far.
(Remember that if you have difficulty seeing the photos to contact me at
[email protected] with proof of purchase and I will send high
quality photos).
Glass bed
When printing, I personally use a glass bed. Glass is far superior to acrylic
due to its ability to remain flat and its lack of warping while heated. I prefer
to use a 1/4” thick glass bed rather than the standard 1/8” glass, though it
will add weight to your Y carriage on a Cartesian machine.
There are various methods to get your part to stick to a glass bed, since
heating alone will not do the trick. These are NOT needed when printing
with a PEI build plate.
Hair Spray: This is my preferred method since it seems to work quite
well and allows for the bottom of the print to retain a high quality shine.
Honing in on the right hair spray is important and I have settled with Aqua
Net Unscented Extra Super Hold. Make sure to always proceed with caution
though, because hair spray is very flammable.
Apply a thin coat as if you were spray painting your bed. You should do this
with your machine off, or with all fans covered as to not have the ambient
spray be sucked into your hotend assembly. If possible, remove the glass
plate and add the hair spray away from the printer, so that the sticky
substance does not get onto the rest of your machine. Be sure to avoid
spraying the rods, because they should remain as lubricated as possible.
Allow the hair spray to dry, heat the bed, and your parts should now stick
with a lot more ease. Removal of these parts is normally quite easy as well,
just wait for the bed to cool to room temperature. If you wait until room
temperature, and you start your print the proper distance from the build
plate, it will actually pop off without much effort at all.
You will run into issues on large ABS and other high internal stress
materials when it comes to warping. Applying hair spray will work for most
circular shaped ABS parts, but any model with corners and a high density
will experience warping, unless you switch to a different material or method
of bed adhesion.
Blue Painters Tape: I do not use this method any longer but it will
definitely work if you are having a lot of issues with your print sticking to
the bed. This method is pretty much required if you are printing on a non-
heated build plate.
Just grab a roll of blue painter’s tape and apply it evenly to your build
surface, while it is at room temperature. Apply as flat as possible and
remove all bubbles. You may have to raise your Z-Height if you were
previously printing straight onto the build plate, since your nozzle will now
drag on the tape during its first layer.
Most materials will stick great to blue painters tape, but removal of these
parts can be quite a hassle. Not only will the underside surface not maintain
a high quality look, attempting to scrape off the part can come to the point
where you rip the tape along with the print, creating quite a lot of post
cleanup.
You will still run into difficulty with large ABS parts, but not as much as
you would with only hair spray.
Glue Stick: I really do not recommend this method, but if you are
extremely frustrated after using the above two methods, you can give this a
go. Parts stick very well when you evenly rub a glue stick onto surface of
your build plate.
This method requires a lot of cleanup, does not allow for a clean underside,
and makes the parts quite hard to remove.
This can also be used for some nylon prints, assuming the glue stick is a
PVA base.
ABS Slurry: If you are printing a large, dense, and rectangular ABS
part without any enclosures or special build plates on your machine, you
will almost certainly need an ABS slurry. Please keep in mind I almost
never do this anymore, since I have switched to either PETG, PolyMide
CoPA, or other materials rather than printing in ABS in order to avoid this
annoyance. ABS is not nearly as common in the 3D printing world as it
once was due to the emergence of these materials over the past few years.
To make an ABS slurry, grab a clean non-chemical reactant bottle, such as a
disposable water bottle or glass mason jar (must have a sealed lid) , then
toss in bits of ABS. You will want to use the same color ABS of the print
you will be fabricating. You can use failed prints, past support material, or
just break parts of the filament up right off the spool.
You will want to then add roughly 100mL of acetone per 10g of filament.
This is why it is crucial that you are using a container that is not reactant to
acetone. Then seal the container tight and wait a few hours until the large
chunks of filament are dissolved, and you are left with a nice slurry.
You will then brush this slurry onto a room temperature build plate. Make
sure it is not heated because acetone vaporizes at low temperatures, is
flammable, and is not good for your health.
You can now print large ABS parts without much issues. The bottom of
these parts will not be clean and you will still experience layer separations
if printing a tall piece in an unenclosed printer. You will only get one print
from this coat of slurry, so you will then have to clean the build plate and
reapply. Cleaning consists of acetone and a decent amount of scrubbing.
Be very careful when using this method with a glass bed. The adhesion to
the bed will be extreme and it is not uncommon for glass beds to shatter or
chip when attempting to remove a part that is particularly stuck to the
surface. Use safety glasses and cut resistant gloves if using this method with
a glass plate.
To be honest, due to the extreme difficulty of printing ABS without
warping, I have essentially switched to PETG and Carbon Fiber blends
when I need a strong mechanical part. I haven’t made an ABS slurry in
nearly 3 years.
Coat of PVA: As mentioned above, most of the nylon materials you
work with will require a coat of PVA being applied to a glass plate. I
personally just use Elmer’s glue mixed with water.
While I have read mixtures of up to 8 parts water to 1 part PVA, I actually
go all the way up to 1 to 1. Get a cup and add some standard Elmer’s glue,
and then add roughly the equal amount of water. Mix this up thoroughly and
then paint it onto the build plate when at room temperature.
This will be very liquidity so you will want to then heat your build plate to
45°C (or whatever temperature your print material calls for), and the water
will evaporate slowly. Do not start your print until you have a dry surface. It
will take about 5-10 minutes to evaporate entirely.
Your nylon parts should now stick much easier. You can also use this
method for PLA and ABS, though I personally do not. In order to clean off
this PVA you do not want to use alcohol or acetone, since it is not soluble in
those. Just use soapy water to clean PVA off your build plate.
I have had difficulty on a couple of nylon mixtures, and ended up resorting
to a glue stick, so keep that in mind as backup.
Third Party Sticky Sheets: There are a few companies that make
sheets that are applied to your glass build plate. These advertise high bed
adhesion with easy removal. But, from what I have found, most of these
products allow your part to stick very well, but do not allow for easy
removal.
The majority of these products will only last for around a dozen prints
because it is extremely difficult to remove parts without damaging the
sheet. I do personally use these though for when I have a lot of prints that
have a very small surface area touching the build plate (imagine a print bed
of 100 skinny posts). I would normally have to use a brim for these types of
prints, but it can literally add hours of cleanup when across hundreds of
parts.
Using these sheets allow for me to print these specific parts without any
brim or fear that anything will get knocked over.
I have a BuildTak bed sheet on one of my machines, and while it works
pretty well, I almost never use it, the only exception being the thin small
parts mentioned earlier. Removing parts is very difficult and I have found
that glass with hair spray works easiest. Keep in mind that these sheets will
likely not work with Nylons.
TH3D Studio offers EZMats which are similar to Buidtak, but should be
easier to use. I personally have not tested these though.
PEI bed
Some printers come with what is called a PEI bed, or you can purchase one
separately. These can be full beds or sheets that you apply, but they must be
used on heated build plates only. A PEI bed will essentially create small
suction cups when heated - which will help parts to stick, and then become
flat when cooled - allowing for very simple removal. The major benefit to
using a PEI bed is that, unlike glass, it does not require surface preparation
before printing (aside from keeping it clean from normal dust and debris).
You will always want to wait until your part is easy to remove or until the
build plate is at room temperature before attempting any removal. If you do
not, you will be far more likely to damage this very delicate material. I have
broken a few PEI beds in the past, so be careful. You will definitely want to
make sure you have the proper initial Z-height, since printing too close can
really damage the material.
You will also want to periodically clean this bed with alcohol, otherwise
you will slowly lose adhesion properties. I suggest cleaning every 5 prints.
If you notice parts are not sticking like they once did, cleaning can normally
fix this. Do not ever use acetone to clean a PEI bed, since it will remove the
adhesion properties.
High quality PEI beds are normally pretty expensive, can be easily
scratched by the nozzle and will all eventually degrade from normal use
over a few hundred prints. Lower cost PEI films will bubble up, and
eventually will get torn from repeated removal - but over the course of a
hundred prints you will likely need to replace this part. I personally do not
use PEI beds any longer, but some of the best printers come with these
stock. There have been improvements in this regard since the last time I
used one, so it may be worth trying one out if you are inclined to.

Using a brim
A brim refers to the lines around the print that act as an anchor. This will be
needed for all high internal stress materials such as ABS, and for most parts
that have a very small surface area touching the build plate.
 You can add a brim in your slicer settings, as
explained further in the “Settings Issues” chapter. As you will read there, I
prefer to only print a brim on the outside of a part. I do this because a
standard brim will add anchor lines to every section of the print touching
the build plate, including small holes. This adds for a lot of cleanup, and
most prints only require this anchor to be applied to the outside perimeter.
How thick the brim is will be based off of the nozzle diameter. A brim of 15
lines will be twice as thick with a 0.8mm nozzle vs. a 0.4mm nozzle. For
most parts requiring a brim I will use anywhere from 10-30 lines. Anything
more than this is unnecessary.
If this brim doesn’t help with very small parts being knocked over, you can
try using a raft, as explained further in the “Settings Issues” chapter.
Initial layer thickness (horizontal
expansion)
You can also increase the thickness of the first layer of the print in order to
help bed adhesion. This is not preferred because it will tweak the tolerances
of the bottom of your print by the amount you increased. If you have pieces
that must mate together, you should not proceed with this method.
If you are OK with the bottom layer being slightly thicker than the rest of
your print, this method definitely works to help anchor your part and
increase bed adhesion.
You can also make this number negative, reducing the elephant foot issue,
as covered in that chapter.
Initial Layer Height
Rather than tweaking the initial layer thickness, you can tweak the initial
layer height to help the first layer lay down properly. If you are printing at
0.1mm layer heights, it is very difficult to get the first layer to stick. The
lower the layer height, the more precise your Z-height needs to be. If your
bed is not perfectly flat, (which is extremely common, particularly on larger
printers) then you may need to use this parameter to get any successful
prints to adhere to the bed.
I have standardized to having the first layer be 0.25mm – 0.3mm on a
0.4mm nozzle, so that I have a lot more leeway on the initial Z-height. This
means my first layer will be 0.25mm - 0.3mm, while the rest will be lower
for a higher quality print.
The rare times I use a 0.15mm or 0.25mm nozzle, this number is much
lower, but still roughly 3x the layer height of the rest of the print. Getting
the first layer to stick on a 0.15mm nozzle and 0.05mm layer heights is a
task that will definitely give you a headache.

What to do when this happens

What you see above is the result of an overnight print that lost its bed
adhesion a couple of hours in. The ways to prevent this from happening are
all of the methods mentioned earlier in this chapter, but once it happens,
you have quite the cleanup on your hands.
If your issue is not quite as bad as mine, you can just heat the nozzle to a bit
higher than extrusion temperatures, and clean up using a set of pliers. If it is
as bad as mine, you may end up needing to purchase some new parts.
You will need to disassemble all of the parts affected. If you do not want to
spend time torching material, you can just purchase a new hotend,
thermistor, and heater and assemble them in. You will actually want to try
and use a heat gun before a torch, it is just the material that I am using in
my example has a very high melting temperature. Make sure to use a heat
gun if you can in order to have a much higher chance of salvaging parts.
To salvage as many parts as possible, you will need to get to a well-
ventilated area with a mask and torch. Make sure your affected areas are
disconnected from the printer, or that the machine is off and disconnected.

You need to clearly take the proper precautions here, but there isn’t really
an easier way to get this stuff off when it’s this far gone. Make sure you
avoid ALL wires, unless you just plan on replacing them. Essentially you
just need to use your heat gun and slowly pull everything off. If you can’t
use a heat gun, torch for a couple of seconds, and then use your pliers to dig
in.

After digging in for a few passes, you should be able to eventually get the
entire chunk off at once. If you are able to heat your hotend, make sure it is
hot for easiest removal (which is obviously not possible if you already cut
the wires for replacement). Using a heat gun increases your chance of
salvaging everything.
It ends up that I needed to use a new heater block, heater, and thermistor in
this instance. Even after taking the time to remove the material from the
heater block, I was unable to remove the heater and thermistor because the
screws were stuck in place. I could have spent another couple of hours
torching until everything could be removed, but I figured it was not worth
the time.
You can purchase a replacement heater block, heater, and thermistor on
Amazon or MatterHackers, and you will then need to re-connect it all. You
can just cut the wires and then solder the new set. Please check the
“Important Accessories and Replacements” chapter of this book for ways to
connect wires.
Be careful assembling again, and reprint any parts you may need. It ends up
I also needed a new barrel cooling fan, so make sure you purchase all
replacement parts required. This need for new parts is why it is really
important to get your bed adhesion right before walking away from it for
hours at a time. Avoiding this 2 hours cleanup and $25 in parts is definitely
the preferred method.
It is very possible you have a clogged nozzle or barrel after this, so if you
do – follow the steps in that chapter.
I also have a video on this exact issue where I go into further detail – titled
“Repairing a Gunked Up Hotend” on my 3D Print General YouTube
channel.
Summary of Fixes and Precautions:
Know the material you are using (what are the print settings and
limitations, including warping chances)
Heat your build plate to either the glass transition temperature of the
material you are using, or to a specific temperature suggested by the
filament manufacturer
Frequently clean your bed before applying any extra adhesion to
remove fingerprints and residue from previous prints.
Use either a ¼” glass build plate with a coat of hair spray, or a
heated PEI bed without any extra adhesive substance
Hone in the proper initial Z-height, since the first layer requires the
nozzle be a proper distance from the build plate
Create an ABS Slurry if you are printing a large ABS part in a non-
enclosed printer on a glass bed
Slow down the speed and turn off active cooling for your first layer
Print with a brim if the corners are curling, parts are being knocked
over, or if you are experiencing warping
Print with a raft to help even more than a brim
Increase the initial layer thickness if having lots of problems with
bed adhesion – though this is not really suggested on normal parts
Increase the initial layer height to max out your nozzle diameter
(75% the nozzle diameter) so that the tolerance on your initial Z-
height is a lot easier to hone in.
If you are left with an overnight mess on your hotend, use a heatgun
to remove and clean everything.
Build Plate Not Heating
As with your hotend not heating, this failure is very easy to diagnose since
your build plate will not heat up, or will turn off instead of maintaining a
temperature. It seems that this issue comes up more frequently than your
extruder not heating because more power is required to heat your build plate
due to its size. This is particularly true for Cartesian printers which require
the bed to have high acceleration moves in the Y axis, which can accelerate
wear on the wiring.
After you confirm you are using the correct volt/amp for your heater/board
combination, you can move forward to checking the following issues.
Many of these instructions are similar to the “Hotend Not Heating” chapter
in this book.
Heater malfunctioning
The heater for your build plate is normally either a thick material stuck to
the underside of your bed, or is its own separate surface. This heater will
have thick gauged wire soldered onto it, which will transfer the power to
provide heat.
The easiest diagnosis for when your heater is malfunctioning is to see if this
connection has been frayed or destroyed. Frequent usage of your machine
(especially Cartesian ones) or other unforeseen problems, can cause this
cord to be pulled and tugged from its connection on your heater. Make sure
your power is turned off and your machine is unplugged, then take your
build plate off so you can easily see the underside of the heater. If you
notice that a wire has been pulled from the bed, or is not connected strongly,
you will have to solder it back on properly, or purchase a replacement
connector.
Most heaters are very simple resistive elements, so it is pretty rare to find
that the heater itself is not working. It is recommended to proceed to the
next steps before purchasing a new one.
DO NOT REPLACE A HEATER CORD WITH A NORMAL SMALL
GAUGED WIRE (thinner than 14 gauge) YOU WILL BE SUSCEPTIBLE
TO A FIRE AND FURTHER BURNT OUT WIRES. KNOW THE
AMPERAGE OF YOUR HEATER AND SIZE YOUR CORDS
ACCORDINGLY.
Burnt out connectors or wires
If the wires are connected to your build plate properly, you will want to
check the cords for any disconnections or burnt out areas. When a build
plate goes out, it is common for this to happen. When a connector or wire is
burnt out you will not get any heating out of your build plate, unlike what I
describe in the next section. This is something that has occurred on a few of
the machines I have worked with.
If you find any burnt areas, you will have to cut that section off and solder
the wires back together – making sure you get continuity on your
multimeter after. Make sure to have your machine off and unplugged, and
use the proper shrink wrap or correct gauge solder seal connectors.
Absolutely no metal can be exposed after this process. Then confirm that
the build plate can reach its farthest point from the board, because you just
made the wire shorter than it was.
If your newly soldered wire cannot reach the board at the build plate’s
farthest point, you will experience layer shifts on large builds. In this case,
it would be recommended to replace the entire wiring harness or add a
length of wire to the harnesses after cutting out the burnt section. Avoid
accumulating multiple solder joints on a single wiring harness as that will
lead to increased resistance on the line and lower heating times. If replacing
the wire, grab the correct gauge and see if you can get a wire with flexible
silicone insulation to help prevent this from occurring in the future.

If you see that the connector that is plugged

into the board is burnt out, you will need to replace it.
This is extremely common on the power input for RAMPS boards, and can
be referred to as a design flaw. The connector that comes with the board is
easily overheated and can melt, which is exactly what happened to me on
one printer that I built. I had no active cooling fan on the board, so if I
didn’t notice it early, I could have had a real issue on my hands.
Historically, RepRap boards don’t use connectors that are rated high
enough. If you are using a RAMPS board, I can’t suggest enough that you
upgrade the board terminals to a well-made 16A replacement (which can be
found at Digikey or Mouser). This should not be an issue on most pre-built
machines, and more common if you were to build one yourself.
Remember that the area you are replacing may have some melted plastic, so
you will need to clean it out entirely before attempting to reconnect. If
replacing the connector does not fix this burnt out area, you may
unfortunately need to replace the entire board.
Only after everything is wired properly and there is no exposed metal
should you plug everything back on and test to confirm the build plate is
heating again.
Board overheating
During this particular failure the bed will normally start to heat - and then
randomly turn off. This may not even cause a failed print at all - depending
on when the heater goes out, how large your model is, what bed adhesions
you are using, and what material you are printing with. When your board
overheats mid print, you likely will not have a lot of cleanup on your hands
-as you would when the hotend loses heat - but you can experience a
warped part.
If you only pay attention to the beginning of a print and then come back
when it is completed, you may not even notice that your board overheated.
Run a print on a hot build plate (such as printing in ABS) and pay attention
to when, and if, the heated build plate starts dropping in temperature.
You can normally tell if this is happening by checking the temperature of
your board when the heater cuts out. Be careful though, because if the board
is overheating, it will be hot enough to burn your fingers.
I go over a few of these methods elsewhere in this book, but if you are
experiencing a board that is overheating, you will need to get 1-3 active
fans blowing right onto it. If your board is enclosed with the rest of the
machine, the build plate heating will drastically affect the ambient air
temperature, causing much more frequent times your board can overheat.
This is why you will want your board located outside of any enclosed
printers. Small heat sinks will always help affected areas, but from what I
can tell, setting up some active fans make the biggest difference.

Most manufacturers come with fans blowing on the board stock, but they
can go out or not blow as fast as they should over time. Make sure to
regularly check that any active cooling fans are free from excessive dust
and debris, which can cause them to fail.
If your board is constantly overheating, or you are using a RAMPS board
with thousands of hours of printing on it, you will want to replace it
entirely. RAMPS boards are normally extremely cheap at under $10, but
higher end boards such as a Rambo board may be closer to $150. These
higher end boards will experience less overheating when wired correctly.
Purchasing a printer from a reputable manufacturer, such as the ones
covered in the “Resources” chapter, should not experience these issues,
though you will periodically want to confirm the fans are blowing properly.
Purchase a new heated build plate
As mentioned earlier, it is very rare that you will need to do this. In fact, I
have used over 20 machines for over 75,000 hours of printing and have only
had to replace two heated build plates. Since these are normally a bit more
expensive than replacing many other parts, confirm that you have tested all
of the above methods before purchasing a replacement.
Build plate will only heat
I decided to throw this in even though it is a bit of the exact opposite
problem as the rest of this chapter, I just wasn’t sure where to include it. If
your build plate decides to start heating when you turn on the machine,
without telling it to heat, then you have a faulty MOSFET. The MOSFET
that controls the board failed, and when they fail they normally turn to
“ON”, which means the board will attempt to heat right when you turn on
the printer.
If the MOSFET is attached to your board, you will unfortunately need to
swap the entire board. If the MOSFET is external, you can go ahead and
change it.
Summary of Fixes and Precautions
Confirm you are using the correct Volt/Amp for your heated build
plate/board.
Check to see if cords have been ripped off or have poor connection
to the build plate.
Check for visual damage (burnt out cords/connectors).
Solder or rewire sections of wire that are disconnected or burnt out –
always using the proper gauge.
Confirm you have connectivity in the wires from the board to the
heated build plate via a multimeter.
Replace any burnt out connectors to the board.
Actively cool your board.
Replace board if overused or burnt out.
Replace MOSFET if your build plate will start heating without you
telling it to, and replace the whole board if the MOSFET is onboard.
Build Plate Not Reading Correct
Temperature
At times this problem can be pretty difficult to diagnose, and just like when
your hotend isn’t reading the proper temperature, if left unattended it can
lead some serious issues.
These instructions are very similar to the “Hotend Not Reading Correct
Temperature” chapter.
Build plate reading 0° or you receive a bed
not heating error
There is a thermistor for your heated build plate that works as a
thermometer - and just with the hotend’s thermistor - it can become
damaged or disconnected. These thermistors are not very expensive, but can
be difficult to replace on certain setups - so while it is good to have a spare,
you will likely want to test everything else first.
If your thermistor has no physical damage that you can see, you will want
to check for continuity in the wire. If there is a frayed wire, or a section of a
wire you can diagnose has no continuity via a multimeter, you can cut and
solder skipping the section – or rewire entirely. If your thermistor is still
intact, replacing the wiring will likely fix your issue. When repairing the
wiring you will then need to confirm that the build plate can reach its
farthest point from the board, because you just made the wire shorter than it
was.
If your newly soldered wire cannot reach the board at the build plate’s
furthest point, you will experience layer shifts on large builds.
Note: if you are in a pinch, soldering the thermistor line will work but it
may lead to additional process issues since you are changing the resistive
value of that line and therefore the temperature that the board is reading.
Your material profiles may require slightly different temperatures after
doing this. It is typically recommended to completely replace this section of
the wiring if possible.
Confirm thermistor is attached properly
Well-built machines will have their thermistors attached snugly to the build
plate, but cheaper machines may only be held onto your heated platform by
some Kapton tape. Constant moving and shaking of your build plate can
make it so this tape becomes disconnected, and your thermistor will
inevitably shake out of its holder.
This will cause your thermistor to read a lower temperature than your build
plate actually is, since it is not actually touching it. This problem can
become severe if the thermistor gets far enough from the build plate, which
can cause your heated platform to continue to rise in temperature until your
board overheats.
You need to confirm that your thermistor is attached properly to the build
plate and that there is no chance of it being ripped out mid print.
Having a build plate that is off by 5 degrees typically will not really affect
the quality of your print, but it can definitely become an issue when the
differential gets more than this.
Still experiencing issues
If you are still experiencing issues, or you notice that your bed is
continually 10 or more degrees off from where it should be, you will likely
want to replace your thermistor and rewire it from the build plate to the
board.
If the problem continues, flash your machine with the original firmware,
and then replace the board if necessary. Replacing the board should be a last
case solution.
Summary of Fixes and Precautions
Make sure the thermistor is actually connected to the build plate and
not hovering next to it.
If thermistor is noticeably damaged, replace it.
Check for breaks or frays in your wire and solder or rewire as
needed.
Make sure that if you do rewire, you give enough slack to allow the
build plate to move to its farthest point.
Replace and rewire thermistor from the heated platform all the way
to the board.
Flash firmware to factory settings.
If still malfunctioning - replace board.
Built Up Material in Nozzle
If you do not have a specific hotend for every material you are using, you
will likely experience some black dots on your prints from time to time.
Even when you are using only one material, this can still be a frequent
occurrence.

One of the
biggest issues with this failure is that you will often not be able to diagnose
it until it happens. This means that a black spot might show up on an
important section of your piece 10+ hours in. This is why it is crucial you
maintain the cleanliness of your hotend by frequently purging and cold
pulling out any residue from your nozzle, along with using a nylon brush.
Ensure your hotend and nozzle is set up
properly and tight
Every hotend setup needs to be assembled in a slightly different fashion, but
nearly all of them require you to not over-tighten. This precaution to not
over-tighten can lead to gaps between the nozzle and heater block if you
assembled everything while at room temperature.
When the heater rises in temperature, the metal expands and can cause your
once tight nozzle/heater block to actually have minor gaps. This gap can
cause material to ooze out and make its way onto your print. Since this
material has been stuck on a hot nozzle before finally being pushed onto
your model, it will likely be black and burnt, regardless of the color you are
using.
If you notice that your heater block is loose when hot, or that you constantly
have to brush off the nozzle or hotend from excess material, you will likely
need to tighten these parts.
I always suggest doing the final tightening of your nozzle and heater block
when heated to 240°C, using proper gloves and tools. Remember that you
have a high chance of burning yourself, so only do this with extreme
caution.
You also want to make sure to not over-tighten anything. I have broken
quite a few heater blocks, nozzles, and heat break barrels due to over-
tightening and not being careful. These parts, especially when hot, can
easily snap under pressure. When you are doing this, make sure to only
tighten until you know that the nozzle and heat block are not loose, and will
not unscrew during the print.
If you still are experiencing material oozing from the gap between your
nozzle and heater block you will likely need to upgrade or replace your
nozzle, heater block, or entire hotend. Poorly made or worn out parts will
not have tight tolerances, and can lead to these gaps in your threads. I have
seen images of cheap knockoff products cut in half showing just how poor
their tolerances are.
This is why it is important to only purchase name brand parts and not to buy
Chinese aftermarket knock-offs. For example, if you want an E3D hotend,
only purchase from verified dealers such as E3D, Filastruder or
Matterhackers because there are many counterfeit products on the market.
Matterhackers is a good source for most 3D printing parts.
Purging material
Every time you switch filaments, after very long prints, or when switching
between different materials, you are going to want to purge out the material
that may have oxidized inside of the hotend. There are a couple of ways that
you can do this.
If you are using the same material, you can go ahead and heat the hotend to
its printing temperature. You then push down the filament for about an inch,
and then pull up quickly. Cut off the end and you should be good to go with
your next print. Repeat this step as necessary if you are switching to a
different color in order to ensure that you do not get any mixed colors
during your print.
If you are switching to a material that prints at a higher temperature (such as
switching from PLA to ABS) purging is normally simple. You will want to
do the same procedure as above, just perhaps do it multiple times in order to
confirm that no remaining residue within the hotend. If this hotter material
is in a different color, then you will follow the same procedure, it will just
be more apparent when you haven’t purged enough. Since you are printing
at a higher temperature, the majority of the previous material should be
removed.
A real issue occurs when you are switching to a material that prints at a
lower temperature than your previous filament (such as switching from
ABS to PLA). It is likely you will not be able to purge all of the residue
material with the above method, because the ABS needs to be purged at a
temperature it can properly extrude at.
If you like to live dangerously, you can purge this material by pushing the
colder filament through the hotend when it is set to the higher temperature
(such as extruding PLA at 235°C when switching from ABS). Push the
material through at a steady pace and then pull it out very quickly, making
sure to not let it sit. If you attempt this method, you are going to have a
higher chance of a nozzle clog, and you may not get 100% of the residue
material.
The proper way to get rid of this material would be to do a Cold Pull as
described below, or to purge by using a cleaning filament/nylon material.
Purging with cleaning filament or nylon can be done by heating your
extruder to a temperature of around 240°C – 250°C, and then extruding the
cleaning filament through as you would with the examples above. Quickly
pull the filament out as to not leave any residue, and you will see just how
much gunk cleaning filament was able to pull out.
Though less common when using cleaning filament than with other printing
materials, you still run the risk of leaving residual material in the hotend
that will come out later as a black, burnt spot.
Cold pull
When switching to a material that prints at a lower temperature than your
previous filament you will likely want to do a cold pull. Cold pulls are also
very beneficial to do as regular maintenance on your machine regardless.
I personally like to perform cold pulls with either a cleaning filament or
Nylon mix, but you can perform them with the material you are trying to
clear out. My favorite material to do this with is actually Nylon 910 by
taulman3D. Not only is that material great to print with, it seems to work
even better than cleaning filament I have used in the past for removing the
oxidized material in the hotend.
What you will want to do is heat the hotend to the temperature of the
material you are using to do the cold pull (250°C for Nylon 910). Push the
filament through for an inch, or as much is required for you to no longer see
the previous material coming out the nozzle.
Then quickly set your hotend to 140°C - 160°C. You don’t want to leave the
material sitting in the hotend for a long period of time because it can
oxidize itself, or even cause heat creep in your barrel. Once the nozzle cools
to this newly set temperature you will want to pull out the filament. This
can be difficult if there is a lot of built up residue material, but it normally
doesn’t require too much effort.
Once you pull you should see excess burnt or colored material on the
filament you just cold pulled. Repeat this process until you no longer see
this residue.
This is the best way I know of, other than purchasing a new hotend/heater
block, to get rid of the excess and oxidized material.
Use a wire brush to clean nozzle and
hotend

You should have a brass or copper brush

on hand to clean the nozzle and hotend periodically. Before a print,
especially one where you see material has built up on the heater
block/nozzle, you will want to clean it with a wire brush (when heated).
When the nozzle is hot you can brush off any excess material that has built
up.
Many people suggest using a nylon brush instead of a wire brush since it is
far less abrasive. I will use a nylon brush frequently and only periodically
use a wire brush on a very dirty hotend. If using a metal wire brush it is
better to use one made of copper or brass as opposed to steel to reduce the
amount of nozzle abrasion that occurs.
If you use a brass brush, make sure you heat the hotend and then cut the
main power before brushing. If not, you can short out the thermistor and/or
kill the board. Don’t just turn off the heating, turn off the entire printer as to
prevent a board from shorting.
This is crucial in maintaining a clean nozzle and reducing the amount of
burnt spots experienced on a print.
Don’t leave filament resting in a heated
hotend
You shouldn’t heat your hotend until you are ready to extrude. If you leave
filament in a heated hotend for long periods of time you will increase your
chance of nozzle clogs and oxidization of the material. This is a surefire
way to increase the amount of times you will see burnt black spots on your
print.
Make sure all of your end G-codes have the script M104 S0, which turns off
your hotend after completing a print.
Use a silicone sock if available
One great improvement done by E3D for their hotends is adding a simple
silicone sleeve for the heater block and nozzle. This blue sleeve fits right
over their heater block and does not melt at normal extruding temperatures.
Many other manufacturers now also offer this feature due to the success
from the E3D socks.
As mentioned in the “Hotend Can’t Reach or Maintain a Temperature”
chapter, these socks help to keep the hotend from sporadically changing
temperatures, but that is not their best feature. The greatest part about these
sleeves is the extreme reduction in black burnt spots on your prints. Your
heater block and nozzle will remain in shiny clean condition so long as you
print using the sleeve.

Black burnt spots are still possible due to the fact you
can have oxidized material built up in the heater block, but the problem
should be vastly reduced. The only negative I have found from these
sleeves is when attempting to print with a large diameter nozzle in a draft
resolution. When I print on a 0.6mm nozzle at 0.4mm layer heights I always
remove this sleeve. This is because the thick layer heights increase the
probability that the sleeve will get in the way of the print and be knocked
off.
E3D now makes silicone socks with a large hole for the entire nozzle to fit
through, which can be used when printing at these larger layer heights.

Excess material built up on nozzle

 The two
examples shown above have an extreme amount of material stuck to the
nozzle. This is caused via letting a part that is not stuck to the build plate
continue to print. Once a part is knocked off or does not have the proper bed
adhesion, your printer will continue to print, and thus, build up material all
over the hotend.
Please refer to the “Bed Adhesion” and “Parts Being Knocked Over”
chapters for ways to prevent and clean this, since this isn’t exactly the same
problem described in this chapter.

Summary of Fixes and Precautions

Make sure you have a well-made hotend and that everything is
tightened when heated to 240°C. Take proper precaution to not over
tighten.
Purge old material by pushing down new material an inch and
pulling out quickly. Cut off any old material that is stuck onto the
filament and repeat the process until there is no longer any excess
residue.
Use cleaning filament or Nylon 910 since it works best for this
process.
Cold pull by extruding cleaning filament/ Nylon through the hotend
at 250°C. Allow the nozzle to then cool to 140°C – 160°C, and pull
the filament out. Repeat this process until you no longer get
discoloring.
Don’t leave filament in a heated hotend for extended periods of time.
Use a silicone sock to reduce black spots on your print.
Electrical Safety
Let me first state my thanks to Timothy over at TH3D since he does quite a
lot for the 3D printing community. One area of his expertise resides in
upgrades and proper precautions for 3D printers, which many 3D printer
manufacturers overlook. Please also refer to Thomas Sanladerer’s video
“Everything you need to know to make your 3D printer fireproof!” on
YouTube for an even more detailed description of everything in this chapter.
Always remember, 3D printers are machines and not toys, regardless of
how they are advertised. Inside the electronics of your machine you will
have high voltage coming from the wall (AC power) and then lower voltage
that comes out of your power supply (DC power). When working on your
machine you should always have the power disconnected and AC cord
unplugged from the wall.
While the lower cost 3D printers are great bargains and are helping millions
of people get into 3D printing who weren’t able to in years past, there are
some key wiring issues present on most lower end brands that should be
addressed before using them long term.
Build of your printer
While the actual frame of your printer will likely not be the catalyst for a
fire, it can help to contribute to it. This really isn’t a problem anymore with
the advancements in the industry, but many low end printer frames used to
be made out of wood or acrylic. Wood would obviously make the situation
worse, and acrylic also burns quite well.
You can help to mediate any issues when using an all metal frame. Not only
are all metal frames preferred for their sturdiness, they also contribute to
electrical and fire safety. Luckily, the majority of 3D printers built today
have a metal frame.
Even on a metal frame there are plastic printed and injection molded parts
that are not flame retardant. As an extra precaution, it is recommended to
print in a flame retardant material when making parts for the frame of your
machine. Anything that helps to slow down and prevent the potential of a
fire spreading is beneficial.
The next part of your printer that needs to be checked is how the wiring is
travelling from your board to the parts on your machine. Not only should
these wires be organized so they cannot be tugged on during printing, but
they should be insulated with a flame retardant material if possible. This
can drastically help to prevent any fire that may begin.
You must also consider the operating environment of the 3D printer.
Making a wooden box enclosure is not a smart idea. Keeping your printer
right below curtains is also not a smart idea. Having your printer in an area
that is well ventilated and not next to flammable objects is the best move
you can make in this regard.
Make sure your screw terminal
connections are not tinned
The first thing that should be checked on your machine is to ensure that the
wires going into the screw terminal connections are not “tinned”. These
power connectors are on your board and where your wires from your printer
motherboard connect to.
Tinning is the process of dipping the ends of the wires into solder to make
sure the wires stay together. This speeds up assembly for the manufacturer
and cuts costs down. The issue is that screw terminals should be used with
either bare wires or crimp ferrules. Crimp ferrules are ends that you can
place on bare wire that compress the strands into a metal end. These are the
best case scenario but require the ends and a special crimp to install them.
The free alternative is to cut off the tinned ends and strip the wire to expose
the bare wire. You can then install the bare wires directly into the screw
terminals.
The issue with tinned wires is that when you tighten down the screw
terminal it will deform and crack the solder. Then, as current is going
through the wire, the solder heats up, expands, and then contracts - leaving
a gap inside the terminal. This means that there is little to no contact
between the wires and the terminal, which will make a weak connection.
Once this happens the electricity will arc inside the terminal, creating a
large amount of heat that will melt the terminal. This can result in the
printer not working correctly, or even worse, starting a fire.
All wires that are connected to a screw terminal need to be very tight, to the
point you are unable to pull them out with your hands. Check your
terminals every so often if you are concerned about this, and if they
continually need to be tightened, you do not want to use them. You can get
some crimp ferrules, or worst case, solder directly to the board bypassing
the terminals entirely.
 Underpowered Connectors
As mentioned in other chapters, this is extremely common on the power
input for RAMPS boards, and can be referred to as a design flaw. The
connector that comes with the board is easily overheated and can melt,
which is exactly what happened to me on one printer that I built. I had no
active cooling fan on the board, so if I didn’t notice it early, I could have
had a real issue on my hands.
Historically, RepRap boards don’t use connectors that are rated high
enough. If you are using a RAMPS board, I can’t suggest enough that you
upgrade the board terminals to a well-made 16A replacement (which can be
found at Digikey or Mouser).
This is actually a very common reason for 3D printer fires. As with other
fire potential problems, you should first search the model of your printer
and read forums if anyone has had problems with underpowered connectors
or fires (just as I mentioned the common flaw in the RAMPS board). This
will help you save time if you are not super educated with electronics.
You can also check manually if your connector is under powered by finding
the part number and looking up what it is rated for. These ratings will
include voltage, current, and temperature. The temperature of your enclosed
board will be increased, meaning that the connector needs to work in these
increased temperatures.
If you are using a standard 40-80w heater at 12V, and you wanted to make
sure it’s good for any situation, all connectors for that heater should be rated
at least 8amps at 12 volts, which will allow for anything the heater can
throw at it.
This is actually one of the benefits of 24V printers, since it reduces these
issues. A 24V heater will run half of the amperage when compared to a 12V
heater of the same wattage.
Make sure all of your connectors are from reputable manufacturers and are
rated high enough for the power you are putting through them. A good
design rule is that you should not be using connectors that are rated less
than 120% of the maximum amperage you intend to put through them.
Build plate wiring
Just as with your phone charging cable, the wires coming out of your build
plate will be damaged over time (especially on Cartesian machines where
the bed is consistently rattling). You can get to the point where the build
plate is only being heated by a few strands of wiring that is left, with the
current still being the same across those strands, they begin to heat up more
and more. Severe fraying caused by repetitive motion over long periods can
create a real potential for a fire.
You can help prevent this by creating a strain relief for all wiring harnesses
that experience movement during the print. This will allow the stress on the
wires to be spread out over a distance and prevent a specific section from
having an increased potential of being worn down. Something like flexible
conduit or spiral wrap will work great. Drag chains are the best option, but
they are a bit more difficult to install.
Finally, you can prevent this by using a good silicone flexible insulation for
the wiring. You can purchase new wiring for your build plate and then
rewire it all with this flexible insulation as to help prevent this fraying from
ever occurring.
Heated build plate MOSFET
A MOSFET is essentially a digital switch that turns power on and off. Most
printer build plates will use them on their board to turn on and off heaters.
The issue is that they need to be designed properly for the current you are
trying to drive. A lot of times boards will include an under powered
MOSFET that is not rated for the frequency or amperage it needs to drive,
or are very close to the limitation, without engineering any sort of safety
factor. This can cause a thermal runaway. This is particularly dangerous
when attempting to print in high temperature or poorly ventilated areas.
These MOSFETS can get hot when pushing more power than they are rated
for, and when hot they are also working outside their designed temperature
range. One of the best ways to help reduce this issue is to add a heatsink to
your MOSFET and to add a cooling fan to your electronics. Keeping the
temperature down on your MOSFET will drastically improve your chances
of not getting a fire.
Technically, the MOSFET should not be so hot that this becomes an issue to
begin with. Thermal issues with the MOSTFET would indicate that the
board isn’t using the correctly rated MOSFET. A heatsink and a fan should
help to not make this an issue, but the manufacturer should have been using
a different MOSFET to begin with. You can de-solder and re-solder a new
MOSFET rated for your build plate if this is the case with your printer, but
this isn’t an easy process, and I only suggest doing this if you are
comfortable with electronics. This is why a heatsink and a fan is normally
the easiest solution.
Some build plates on larger printers work on 115V or higher. It is important
to understand the potential dangers of working with AC voltages and are
comfortable working on 115V or higher before touching this equipment. I
don’t suggest this for people not experienced in electrical issues.
Thermal protection in the firmware
Marlin firmware, especially new versions, have thermal protections built in.
This means it can detect if temperatures are outside of the expected ranges
and will automatically turn your printer off. These can be found in the
configuration.h section of your firmware and should be enabled.
One example of thermal protection would be with the MOSFET. Your
MOSFET can fail either when on or off, and this thermal protection can
protect for both. The board checks to make sure the temperature is going
down when the MOSFET is turned off, and if the temperature isn’t
decreasing, the machine will turn everything off as a safety procedure. It
also checks the temperature when the MOSFET is turned on, and if it
doesn’t see any temperature raise, it will cut everything off since your wires
could be dislodged.
Many manufacturers have these disabled but it is a great protection from
anything ever occurring.
Fire extinguishing ball
Finally, the last bit of insurance over your machine getting on fire, is a fire
extinguishing ball. This is a ball that you can hang above your printer that
will explode with fire extinguisher when it reaches a certain temperature,
guaranteed to put out a small flame.
These balls are only around $40 each and I personally have an AFO Fire
Extinguisher Ball above my printers as a last line of defense. You can take
all of the proper precautions but nothing will make you feel quite as safe as
using one of these. You can at least rest assured that your entire house will
not burn down with these above your printers. Remember that many home
insurance providers will not cover for a fire caused by your printer, so $40
is the cheapest insurance you will ever buy, and I recommend it to 100% of
people using a 3D printer.
Elephant Foot

Elephant foot is
an issue where the bottom few layers of your print are much thicker than the
rest of your print. Almost as if the material was mushed out before
correcting itself after a couple of layers.
This is a fairly straight forward issue to fix as there can only be a couple of
causes.
Nozzle too close to build plate
This issue is covered in the “Z-Height Calibration” chapter, but can result in
an ugly elephant foot if not dealt with. When the first layer has the nozzle
too close to the build plate, material is built up, smashed out, and presents
itself as thicker than the dimensions of the actual part. Without enough
distance between the nozzle and the build plate, this issue is going to be
hard to avoid.
The elephant foot would course correct after about 5-10 layers, but the
bottom section of your part will definitely be the incorrect dimensions.
Refer to the Z-Height Calibration chapter to fix this.
Build plate too hot
Another reason this elephant foot failure can occur is from running your
build plate too hot for the material being extruded. I never run PLA with a
build plate hotter than 60 degrees Celsius (sometimes only 50 degrees), but
if you do, you can have a distorted bottom of your print.
This is because you are setting the build plate higher than the materials
glass transition temperature. This means that the material on the bottom few
layers becomes deformed as material is deposited on top of them. While it
is easier to get good bed adhesion at these high bed temperatures, the
deformation causes this elephant foot.
Make sure you are using the proper build plate temperature for the material
you are using by referring to the manufacturer suggestions. If you know you
have the proper Z-height and are operating within the suggested
temperature range, and are still getting an elephant foot, you should attempt
reducing your build plate temperature a bit further. Otherwise you can try
out the next suggestion to make sure this problem is eliminated.
Use a raft

It is rare that I use a raft on my standard DIY machines, but if elephant foot
is a consistent issue, a raft should make this failure disappear. A raft can
cure having your nozzle too close to your build plate, and it can also fix
having the build plate be too hot. This raft acts as a barrier between your
print and the bed and should mean you no longer have any elephant foot
issues.
The photo above has before and after removing the raft on the same print,
and below is this print with a raft (on the right) next to the version with the
elephant foot issues (on the left).

Many printers are meant to use a raft standard in order to help with bed
adhesion, and so long the settings are dialed in, a raft can be a great
solution. It is just something I do not personally use that often because I
prefer the underside of my print to be smooth and glossy.
Negative initial layer horizontal expansion
This is a feature in Cura and may be called something different in other
slicers. The initial layer horizontal expansion can cause the first layer to
have a thicker or thinner expansion. Having a thick expansion can help with
bed adhesion, but will increase your elephant foot issues. Setting this
number negative can help to mitigate elephant foot on parts you are just
having a ton of problems with.
I personally use a raft when this becomes an issue, but going this route
should help as well.

Summary of Fixes and Precautions

Make sure your nozzle is not too close to the build plate by referring
to the “Z-Height Calibration” chapter.
Confirm you are running your build plate within the suggested
temperature range for the material used.
Utilize a raft to mitigate the problem entirely.
Extruder Stepper Skipping
(Extruder Making a Clicking Noise)
Your extruder stepper motor skipping can happen on any setup, but it seems
to be most common on non-geared extruders. A geared extruder allows for
a mechanical advantage that will have your motor spin faster, but have
much less resistance against it.
When using a non-geared extruder you will be forced to run your prints
slower than you could otherwise, so that you do not experience these skips.
Please keep in mind I have never experienced extruder motor skipping on
the dual-drive geared Bondtech BMG extruder, which is just one of the
many reasons I suggest using one.
Is your nozzle too close to the build plate?

If you hear this

skipping on your first layer, it is very likely your nozzle is too close to the
build plate. When the nozzle is too close on this first layer, there is no room
for the material to extrude. Not only will this cause damage to your nozzle
and can even crack your printer bed, it will cause you to hear frustrating
clicking noise. This can also lead to stripped filament on geared extruders
that do not have the stepper motor skipping.
As mentioned in the “Z-Height Calibration” chapter, confirm your nozzle is
homing at the proper height from the build plate before starting any print.
Giving enough room for the filament to be laid down properly on a build
plate can reduce the strain on your extruder and reduce the amount of times
it skips.
Slow your prints down
A common reason your extruder might be making that skipping noise is that
you are running your prints too fast. Your nozzle can only push out so much
filament depending on its diameter. So, just as with bottlenecking in traffic,
you will experience stoppage if you try to push too fast (especially on non-
geared extruders and small nozzle diameters).
This can result in grinding of your filament or extruder stepper skipping.
The general rule of thumb is to not print faster than 100x the nozzle
diameter on non-geared extruders. So if you are using a 0.4mm nozzle, you
should limit your print speeds to 40mm/s, and adjust according to your
performance. This may be slow to some experienced people in the industry,
but is the rough estimate I use for printing on a non-geared extruder. I run
closer to 60mm/s on a good geared extruder such as the Bondtech BMG.
You can test this out mid print if you have a LCD screen on your machine.
Most LCD setups are designed so that when you turn the knob mid print, it
will change the feed rate (speed). If you hear clicking and would like to see
if reducing the speed can fix the issue, turn this knob counter-clockwise. Go
to 90% and lower to see if the skipping is decreasing.
If you still are seeing this problem, you may want to check there is not too
much moisture in your filament, as covered in the “Stripped Filament”
chapter.
Reduce acceleration
The acceleration of your machine is something that is set in the firmware,
but can also be tweaked with certain slicing software - including Cura. You
can tweak this mid-print though if you have an LCD display. Under Control
– Motion you should find the option for Acceleration, depending on how
your board was flashed. You likely do not want this number over 1000 for
an inexpensive machine, and for some Cartesian machines you won’t want
this over 500. Manually reduce this number and see if it helps. This will
also help with ghosting, as covered in that chapter.
If you do not have an LCD screen, or you would like to permanently change
this number, you can find the acceleration in your printers firmware in
Marlin, under the configuration.h tab.

It is easiest to tweak this in the slicing software, as covered in the “Settings

Issues” chapter.

Nozzle Clog
If you have a clog in your barrel or hotend, then you may come across this
issue. Your extruder will be trying to push filament down but will click
when it is unable to do so. Make sure you check the “Nozzle Clogs” chapter
if you are experiencing this.
I have even had minor residue left from switching from ABS to PLA cause
extruder motor skips, especially when working with underpowered, non-
geared extruders. So if you are working with one of these, a cold pull is
suggested after every material change.

Increase the extrusion temperature

Before attempting this, make sure that your issue isn’t being caused by heat
creep (refer to the “Nozzle Clogs” chapter of this book). If you are
experiencing a clog in your barrel due to heat creep, increasing your
extrusion temperature will only make the problem worse.
If you are not experiencing any heat creep and the barrel of your machine
remains close to room temperature, you can try increasing the extrusion
temperature a bit to decrease the chances of your stepper motor skipping.
You will normally not want to go outside the recommended print
temperatures, but there has been a few times I have had to do this to print
properly.
This increase in temperature, so long as you are still within the materials
accepted extrusion temperature range, will allow more filament to feed
through the nozzle at a faster rate.
Loosen the tension on your idler
Most extruder setups have an idler that allows for you to adjust tension –
pinching your filament against the hobbed gear or bolt. This tension is
necessary to prevent filament grinding and to make sure the proper amount
of material is being pushed through the extruder.
While a decent amount of tension is required, you can of course go too far
and have this idler be too tight. When too tight you can actually flatten the
filament, making it too wide to feed. When material is too fat to too feed
you will experience similar issues as you would with Heat Creep in the
“Nozzle Clogs” chapter, or you may experience stripped filament, but it can
also result in the skipping of your extruder motor.
Pinching too tight on a motor that does not have a lot of torque can also
cause skipping at the point of contact. While a tight idler allows for good
grip on your filament, it is harder for the extruder motor to spin, especially
on non-geared setups.
If you notice that the tension on your idler is very tight and you are
experiencing skipping of your stepper, try loosening it a bit. Just keep in
mind if you go too loose, you can experience under extrusion as the hobbed
gear or bolt will begin to slip on the filament.
Making sure filament path is clear
The first step in making sure your filament path is clear is to check for
nozzle clogs and residue in your hotend setup. Any problem you find in the
“Nozzle Clogs” chapter of this book can lead to extruder motor skipping, so
you will want to make sure the path in your barrel is clear from old material
and debris. You can do this by torching out the old plastic in a well-
ventilated area as described in that chapter.
Aside from old material and debris, I am also talking about the actual
pathway that your filament is traveling before being fed through the
extruder. If you have a 3D printed carriage that is warped, or one that is not
to tolerances, you may have a pathway that does not allow your filament to
pass smoothly through it. Any big turns that are required to get your
filament to go down your barrel will add to the difficulty involved with
feeding material. Resistance at the spool or pathway leading to the extruder
will also cause problems.
You may need to print parts (or purchase parts) for a new extruder on your
machine with tighter tolerances and a clearer path to the hotend. This is yet
another reason you only want to buy hotends from reputable manufacturers
that have tight tolerances.
All metal hotends allow for heating without the need of Teflon tubing. This
Teflon tubing can become deformed over the course of a lot of heating,
making the filament path not clear. I always suggest using/upgrading to an
all metal hotend (such as E3D or Micro-Swiss).
Adjust the current to your extruder
stepper
If you are running a board with digital current control, when you flash
firmware onto your printer there is a section that tells the board how much
current is flowing to the steppers. You will essentially want this to the
minimum possible that still gets the job done. This is because going too
high can cause overheating, the driver to run less efficiently, cause wear on
the stepper motor, and results in an increase in noise.
Other boards have a manual current control, including the common RAMPS
board. For these you will need a multimeter and a screwdriver. Please keep
in mind this is only something I have had to do a couple of times and is
very rare that you will need to change. This is only when you know that
there is just not enough power being driven to the extruder stepper. It is
likely smart to switch to a geared extruder before doing this.
You first want to have your machine turned off and disconnect the stepper
motor cable from the board. You then need to look up both the stepper
motor you are using, as well as the stepper driver.
Current limits are determined in the motor and driver data sheet. You will
not want to run higher than either the driver continuous current limit, or the
motor current rating limit, so it is often good to have a driver that has a
higher continuous current rating. I suggest going off of the continuous
current limit of the Motor.
Once you know what current limit you want, you then need to find out the
calculation for your stepper driver to determine a Vref. I had always
assumed the calculations are the same, but they definitely are not. You can
go to the current limiting section of your stepper driver data sheet in order
to figure out the VREF you will want. Current limit will equal Vref x 2.5
for standard A4988, and Vref x 2 for DRV8825. There is then another
option by TMC where the calculation is slightly different, where Vref=
(Motor current x 2.5)/1.77. To find out your ideal Vref, there is a handy
calculator that someone made online which you can search for by typing
“Stepper Driver Vref Calculator”, where you just enter the rated current of
your motor and it will read out the ideal Vref numbers for each driver type.
I understand this is very confusing for someone who is new to this, just as it
was for me. But essentially the Vref is the power that is being sent to your
motors and it can be tweaked depending on your motor and stepper driver
setup. So if your max current limit on your motor is 1AMP, and you are
using the standard A4988 driver, you will have a Vref of roughly 0.4. This
is because 0.4 x 2.5 = 1. This 0.4 would be your target number that your
multimeter will read out. If your Vref is lower than 0.4, you will not be
having enough power sent to the motors, meaning they can result in layer
shifts and motor skips. Going higher than 0.4 can result in an overheated
motor.
To test this out, you will actually need to plug back in your power and turn
the machine on, while you still have access to the board. Be careful now
that everything is on. Make sure the driver you are testing has the stepper
motor unplugged from the board. You would then grab your multimeter. No
real way to do this without a multimeter.
Set your multimeter to 20V DC, and touch your black negative lead to a
ground pin on the stepper driver (titled GND). If you are unaware which the
ground pin is, you can also touch the black negative lead to the negative
section of your power supply. Just make sure to only touch a ground
section.
You can then clip the positive lead of your meter to the metal shaft on the
screwdriver to help read everything out while you change it. If you do not
have a clip to connect the lead to the screwdriver, you will need to test,
tweak, and test again. You then touch the positive lead (or the screwdriver if
you have it clipped) to the potentiometer on the stepper driver. This is a
very tiny screw like object on the driver. You will then see a voltage number
on your multimeter. This is your Vref, which you want to make sure equals
your calculation above.
You can turn the screwdriver clockwise to increase the voltage, and
counterclockwise to decrease (which is actually the opposite on the TMC
driver, so just make sure you are testing after each small turn). A 1/8 turn of
the potentiometer will make a drastic difference in your Vref – so make sure
to not turn too fast.
If you experience overheating after this process, you will want to reduce
this current, but increasing it should help with skipping on underpowered
extruders – just make sure to not go over the rated limits. I suggest you
make sure you have upgraded to a geared extruder and tend to the notes
below before going this route.
Clean the teeth on your hobbed gear/bolt
Your filament is constantly being pinched to geared teeth that grip it and
push it downward. Over time these teeth can be filled with material, causing
them to be smooth rather than to have a grip. You will want to get a very
small wire brush or metal pick and clean this out periodically. Having a
good grip on your material is essential to avoiding stepper skipping and
material slippage.
Please check the “Stripped Filament” chapter for further information if you
continually experience debris on the teeth of your extruder.
Too small of a nozzle
The smaller the nozzle you use, the more likely you will experience stepper
motor skipping. I had a near impossible time printing with a 0.25mm nozzle
and a non-geared extruder. While I didn’t hear clicking (since I was running
the print extremely slow), minor motor skips led to a print looking as
though it was grossly under extruded. E-steps were right on, yet the print
looked as though it was under extruded.
This is due to an increased bottlenecking effect at the point of the nozzle. I
was forced to upgrade to a geared extruder to print with these finer nozzle
diameters. E3D actually advertises that their lower diameter nozzles require
a geared direct extruder to work.
Now that I use a Bondtech BMG extruder, I have zero issues with printing
on nozzles as low as 0.15mm in diameter.
Upgrade to a geared extruder
If you are using a Creality style printer, it is likely the extruder that came
with your machine is a plastic and non-geared. One great upgrade would be
to purchase an all metal extruder, but even better than that would be to
purchase an extruder with a gear ratio.
As mentioned elsewhere in this chapter, a geared extruder, such as the basic
Greg’s Wade extruder, will help to prevent the stepper motor from skipping.
In fact, a geared extruder is pretty much mandatory for printing flexible
materials and for using very fine nozzle diameters.
These gears add a mechanical advantage for increased torque without
adding pressure on the stepper motor - though you will need to increase and
re-adjust your e-steps after switching (Refer to the “Over and Under
Extrusion” chapter in this book).
Upgrading to a geared Greg’s Wade extruder requires a very minimal
amount of extra parts. You can likely find the required printed parts for your
printer and hotend assembly on Thingiverse. These parts normally include a
large herringbone gear, a small herringbone gear that is connected to your
stepper, mount for your hotend and stepper, and some minor hardware
purchases.
Along with various washers and bolts, you will need three 608ZZ regular
skateboard bearings and an 8mm hobbed bolt. Hobbed bolts can be
purchased from NewEgg for about $2, or you can spend a bit more from
places like Amazon or specialty 3D printing stores. You can even make one
yourself by looking up a “how to” online.
Assembly is very easy and all of the printed parts can be completed in about
24 hours on a standard Prusa I3. You will just need to recalibrate your e-
steps after upgrading, but you will want to factor in some basic gear ratios
first. A classic Greg’s wade with a 39:11 gear ratio has e-steps of 500 or
more, unlike 90 where a standard direct drive starts at. If you start checking
your e-steps before changing from 90 to 500, you will drastically under
extrude on your first attempt.
 Personally, I now only use purchased
extruders. I have standardized to either an E3D Titan, or my current favorite
- a Bondtech BMG extruder. The Bondtech BMG has a dual drive, meaning
that both sides pinching the filament have teeth that grab onto the filament,
rather than just one pushing against a bearing. This increased grip really
helps to have proper extrusion and ease to print with smaller diameter
nozzles and flexible filaments. As mentioned in the first section, I have had
0 extruder stepper skips whatsoever since switching. These unfortunately
currently cost $100, and can be purchased over at MatterHackers.com, but I
definitely think they are worth the money for the expanded material and
printing options, with reduced headaches.
Overheating extruder stepper motor
All stepper motors can get overheated, especially when running fast and in
an enclosed machine. It is very smart to purchase some heat sinks and add
them to all of your stepper motors. If you are hearing a clicking noise from

your extruder, and the motor itself is too hot to

touch, you will need to reduce this temperature. A heat sink is the easiest
way to do this, and is another reason working with an enclosed machine can
add to printing failures when not done properly. You can also wire a fan to
blow on this stepper motor if still too hot after adding a heat sink.
In the photo to the left, I have two heat sinks on the side of the extruder
stepper motor, and a fan for the front, as to make sure there isn’t any
overheating on this pancake stepper.
You can also reduce the Vref from your stepper driver, as I went over
earlier, since that will reduce how hot your motor gets in the first place.
Upgrade to a more powerful
stepper/driver/board/power supply
This isn’t needed unless you are still experiencing problems or just want to
run your machine faster than the settings I suggest. Of course, if you have a
malfunctioning stepper, driver, board, or power supply you will need to
replace it - but upgrading these parts will not be needed if you took the
steps listed above. That is unless you would like to run your printer at
extremely high speeds and print temperatures. Printing at 270°C extrusion
temperatures and speeds above 200x the diameter of the nozzle will likely
require a 24v machine, and possibly an upgraded board/driver/stepper
combination.
But you can of course also just order a more powerful board, stepper driver,
and stepper so that you can run more current, causing far less skips in the
motor. Just make sure you understand and purchase everything for the
current voltage provided by your power supply.
Upgrade to a Volcano or SuperVolcano for
large nozzle diameters
This is covered in depth in the “Speed Limitations” chapter, which I suggest
you read if you plan on using a larger diameter nozzle (0.8mm and higher).
Summary of Fixes and Precautions:
Confirm your first layer isn’t too close to the build plate.
Slow your prints down (manually change during print with the knob
on the LCD screen to see if this fixes the problem).
Reduce acceleration.
Print at a slightly higher extrusion temperature.
Loosen the tension on the extruder idler.
Have a clear, straight filament path. Reprint or find more suitable
extruder carriage on Thingiverse if required.
Increase the current to your stepper if not at limit and not
experiencing overheating.
Maintain a clean hobbed gear/bolt.
Increase nozzle diameter if using smaller than a 0.4mm nozzle.
Upgrade to a geared extruder such as a Greg’s Wade Extruder.
Designs can be found on Thingiverse and minor parts purchased on
Amazon, eBay, or NewEgg.
Purchase an upgraded geared extruder such as the E3D Titan or my
favorite Bondtech BMG.
Make sure your extruder stepper motor is not overheating and add a
heat sink and/or fan to help prevent the issue.
Filament Snaps
Another easy to diagnose issue that can be extremely frustrating since it can
happen hours into a print.
Understand the material you are using

Certain materials
have lower elongation than others, meaning they will snap easier on the
spool. Almost all of the carbon fiber blends snap extremely easily on the
spool and will require you to use Teflon/PTFE tubing to guide the filament
and help prevent breaks mid print.
Teflon tubing to guide your filament to the extruder will generally help with
filament breaks and tangles.
PLA has a much lower elongation than ABS, so you will experience more
frequent snaps during the print with it. You can test this yourself since you
should be able to snap a piece of PLA off of its spool, while ABS will
require a tool to cut.
3.00mm filament is also far more likely to experience these issues than
1.75mm filament, as explored in the “Upgrades and Purchasing a New
Printer” chapter. 3mm (or rather 2.85mm) PLA near the end of the spool
can be impossible to print without snapping occurring, which is definitely a
benefit for the thinner diameter.
Properly store your filament
Depending on the climate you live in and material you are using, not
properly storing your filament can cause it to not print properly or break
very easily. If you do not plan on using a spool of filament for a week or
longer, you should store it in a controlled environment. This is likely the
most common reason for filament snapping when it shouldn’t.
You can store this opened filament in an enclosed environment with a
dehumidifier, or vacuum seal it with a desiccant bag. The dehumidifier
should be set to as low as you can (normally around 20%). This is even
more important if you live in an area of the world with high humidity.
This is extremely important when using nylon filaments because they can
easily absorb moisture within hours of being exposed to a high humidity
environment. Low humidity filament containment and feeding systems are
also manufactured for use of highly hygroscopic materials such as nylons.
If you do not properly store your filament, you will need to go through the
steps required to get the moisture out, or even purchase a new spool.
Change manufacturer
If the manufacturer of your filament does not have high reviews, you may
experience frequent breaks. This is when spending a bit more for a name
brand can pay for itself. Hatchbox, E-Sun, Polymaker, Matterhackers,
ColorFabb, IC3D, taulman3D, AIO Robotics, Overture, and Proto-Pasta are
just a few of the filaments providers that should have no problems straight
from the manufacturer.
Without naming any brands, I have had consistent failures and filament
breaks from a few specific lower priced companies.
Loosen idler tension
The tension on your extruder idler may be pinching your filament too tight.
If this is the case, the grinding of filament may lead to your material
snapping entirely.
This would normally lead more to stripped filament, as discussed in that
chapter, but it is possible for it to grind until snapping.
Most extruder setups allow for the adjustment of this tension. You want it to
be tight enough for there to be plenty of pressure, but not too much that it
grinds into the filament or deforms it. If you think this may be too tight, see
if loosening the idler fixes your problem.
Check for nozzle clog
You can be experiencing a nozzle clog if your filament is snapping, so if
this is the case, be sure to read the “Nozzle Clogs” chapter in this book.
Summary of Fixes and Precautions
Know the possibility that the specific material you are using might
break.
Switch to a 1.75mm extruder and hotend setup for less frequent
filament snaps.
Properly store your filament. Using old or improperly stored
material is likely the most common reason for this happening.
Always buy from a well-respected manufacturer for 3D printing
filament.
Replace your spool and try a new manufacturer if needed.
Check for a nozzle clog and fix if that is the underlying culprit.
Gaps in Walls

This particular issue is something I have personally noticed to happen less

frequently on Cura, but it could happen on just about any slicer. This is
when the walls of your print do not connect and can result in gaps.
Why it’s happening
If you’re walls are not designed to be a multiple of the thickness of your
layer lines, you can imagine why this happens. Let’s say your walls are
1.8mm in thickness, and you have your layer lines set to 0.4mm. Your slicer
will either attempt to create 2.0mm walls (5 shells), or it will error on the
lower side of 1.6mm (4 shells), causing a 0.2mm gap. I believe that all
slicers go with the latter, as to avoid printing a part that is too thick.
This gap is normally filled via your infill percentage, or by top layers, but
you may run into issues when it doesn’t.
Each slicer seems to deal with this in a different way. Most will bunch the
shells together on each side of the print, with a 0.2mm gap in the center. I
believe Slic3r does what you see in the photo above, just spreading each
wall out with a smaller gap, though I may be wrong. I personally do not use
Slic3r, but the photo above is from someone who purchased the 2019
edition of my book using Slic3r who had this issue.
If you want your shell walls to fill the entire area of your print, then you
would need the walls to be a multiple of your layer line width. If not, you
can try the following solution.
Fill Gaps Between Walls
Luckily Cura has the ability to fix this issue:

As you can see by the description, this is meant

to fix this exact problem. If the gap between walls is thinner than your layer
line width, this should fill in that area. Simplify3D should have a similar
feature called “gap fill”.
This doesn’t always do the job, but when it doesn’t, normally your infill
percentage will.
This may cause blobs to appear on the side of your print, so if you are
experiencing blobs, you can choose to “Filter Out Tiny Gaps”. Very tiny
gaps, ones you likely wouldn’t notice on your final print, will then be
avoided.
Make your walls a multiple of your line
width
The ideal solution would be to redesign the wall in question to be a multiple
of your desired line width. If this isn’t possible for you, you can slightly
tweak your line width to work.
As with the example in the beginning of this chapter, if you need your shells
to fill up a 1.8mm wall, using a 0.4mm line width will cause a 0.2mm gap.
You can go around this issue by upping your line width to 0.45mm instead.
You will then have 4 lines at 0.45mm, which will be exactly 1.8mm without
any gaps being created.
If you go into your “preview” section of your slicer after slicing, and you
see there is a minor gap in your walls, you can adjust your line width
accordingly. While I normally prefer to keep my line width the same as the
nozzle diameter I am using, you can go up to 120% the nozzle diameter and
not lose much quality, if at all.

The example above has the line width to 0.44mm and it can only fit two
shells (two inner, two outer – making 4 walls), so there is a gap in the
middle of these walls. This part is 2.0mm thick, so you can see why this is
happening. This is even with the “Fill Gaps Between Walls” checked on.
This does go away if you have infill % on, but the above example is with
0% infill. If you require the line width you have selected, then you will need
to have infill fill in that gap.
You can now see what this same print looks like with 0.4mm line width and
no infill:
You can see how that gap disappeared, since at 0.4mm line widths the
printer is able to fit another wall. You then have 5 walls making 2.0mm, the
exact thickness of the part.
You can actually just change the line width of the walls if you choose, so
that it doesn’t affect the rest of your print. Cura allows you to just tweak the
wall line width, or even just the inner or outer wall line width – which is
located in the “Quality” section. This means for the example above, you can
have just your wall line widths set to 0.44mm, and the rest of your print be
0.44mm. You could also set your inner and outer walls at different
thicknesses if it helps you to fill in all gaps with a line width you prefer.

The photo above is showing off an example just like this. The one on the
left was using a 0.4mm line width and the one on the right was using
0.44mm line widths. The math worked out that the 0.44mm line widths fit
without leaving any gaps like the 0.4mm version did.
Potential under extrusion
When none of the walls are touching, similar to the photo at the beginning
of the chapter, you could actually be under extruding. As explained by
Ultimaker on one of their guides for Cura:
“If the walls are not touching each other at all it is an extrusion issue. Cura
is asking your printer to create a series of 0.4mm lines and is spacing them
so that they fuse together. However, if your printer is under extruding
slightly, the lines will be marginally thinner and they no longer fuse
together properly. The solution could be as simple as reducing your print
speed slightly or increasing your temperature a few degrees.”
You can check the “Over and Under Extrusion” chapter for further attempts
to see if this is the issue if just reducing print seed or increasing your
temperature does not fix the issue.
Gaps between infill and walls
This is a different issue than the one explained in the rest of this chapter.
The most common reason for there being a gap between your infill (or
top/bottom layers) and the walls, is the infill overlap percentage being set
too low. I normally will keep my infill overlap percentage around 7 or 8%,
but some people suggest going up to 30%.
I normally don’t suggest doing this since it can lead to a “veiny” print, but
you can also choose to print “Infill Before Walls”, which should help to
make the infill attach to the shell walls.
Summary of Fixes and Precautions
Choose to “Fill Gaps Between Walls” on your slicer.
Attempt to make your walls a multiple of your line width.
Check to see if you are under extruding, and perhaps slow down the speeds
of your shell walls.
Check your infill overlap percentage when dealing with gaps between your
main part and the shell walls.
Ghosting
Ghosting in printing essentially refers to an “echo” where details in your
print can be seen outside where they should be, which may also be called
“ringing”.
The number one reason this occurs is having your acceleration and jerk
settings too high. This is extremely common in 3D printing, especially since
many printer manufacturers will auto set the default value for these
numbers too high, since it will allow them to advertise faster printing times.
A part with some minor ghosting is still entirely useable, so printer
manufacturers may get away with calling something a successful print that
we as makers would be upset with.
Keep in mind this issue should be reduced on a CoreXY or Delta machine,
since the increased weight of moving the print bed on Cartesians will make
this problem worse.
Reducing jerk and acceleration

As you can tell

from the photo above, there is a drastic difference in ghosting between the
two examples. These parts were printed with every slicer setting being the
same, except for Jerk and Acceleration.
Acceleration is pretty self-explanatory, but jerk refers to something you
may not know unless you are involved in the 3D printing sphere. Jerk refers
to the initial speed after a directional change. After stopping and starting
again, your printer will start instantaneous at your jerk speed before then
accelerating to your print speed.
The failed print on the left had accelerations of 3,000 m/s ² and a jerk of 30
mm/s while the print on the right had accelerations of 500 m/s² and a jerk of
12 mm/s – all other settings being the same. It has become clear to me that
jerk and acceleration are the key factors when it comes to reducing
ghosting.
The print on the left took 1 hour 36 minutes and the print on the right took 1
hour 50 minutes, so it is clear you will need to wait longer for your print to
finish, but it is definitely worth it to have the quality you expect.
Controlling jerk and acceleration right in
Cura
As mentioned elsewhere in this book, the newer versions of the Cura slicing
software is updated frequently, and it now allows for jerk and acceleration
control.

This allows you

to change these numbers without having flash your firmware. In Cura, this
is located under the “Speed” section. If you prefer not to use Cura, then you
will have to check within your slicer if this option is available. If it isn’t,
you will have to manually change the Jerk and Acceleration within Marlin
and reflash your firmware. These numbers are right within Configuration H:
You can also find out your current acceleration numbers by typing “M503”
into Repetier Host or Octoprint, which will read out all of your current
firmware settings.
Add small cushions under printer feet
This is a very minor, but easy addition to your printer to help reduce
ghosting. Part of the problem with ghosting is the rattling that occurs within
the printer without anywhere to disperse it. If you have a very sturdy printer
on a sturdy print area, most of the rattling ends up locating within the
machine.
An easy fix is to grab some small foam cubes and place them under your
printer feet. This will help to disperse vibrations through the machine into
the pads, allowing you to print higher acceleration and jerk speeds with
reduced ghosting.
While I have these pads on my printer, I still do not print faster than roughly
800m/s² accelerations and 15mm/s jerk on my Cartesian setup. Remember
that CoreXY can have much higher acceleration and jerk settings without
an increase in ghosting.
Having a lighter carriage
The lighter the carriage, the less ghosting you will experience. This means
ghosting will be more of an issue on a direct extruder than a Bowden. I will
still always prefer direct extruders to Bowden due to the extra amount of
materials available to print, but one of the benefits to Bowden is the reduced
weight.
You can also reduce the weight on your carriage via a smaller/lighter
extruder stepper and/or carriage. In fact, as of editing this book E3D just
announced their brand new Hermes extruder/hotend, which may be
available by the time you are reading this. Hermes is an extruder and hotend
built in one package, with dual drive gears for the extruder, all of it being
much lighter than having them as individual parts.
Belts too tight
Having belts too loose can cause Z-wobble (or even layer shifts), but going
too tight can cause ghosting. There is no specific standard for how tight a
belt should be, but I generally say they should be tight enough to have no
droop and be springy to the touch. If they are so tight it is actually
stretching out the belt, it can cause a reduction in dampening and add to
your ghosting problems.
As mentioned elsewhere in this book, I have had far more problems with
belts being too loose, so I would test the other suggestions in this chapter
before you go loosening belts.
Having too tight of a frame
You almost always want to have a well-built, strong frame. Unfortunately, if
you do not have any dampeners for your axis, this means that the vibrations
from your machine won’t be as dispersed, resulting in increased ghosting.
Having this be too loose can result in Z-wobble – as covered in that chapter.
This means you are going to be trying to find the happy medium where you
get no Z-wobble and no ghosting, something fairly hard to achieve (and a
reason CoreXY is preferred over Cartesian).
You don’t want to go loosening screws on your machine in order to allow
more dampening, which means it may be difficult to do much about this,
other than adding cushions below the printer.
Please refer to my video titled “Reduce Ghosting in 3D Printing” on
YouTube for further information.
Summary of Fixes and Precautions
Reduce your acceleration and jerk via Cura or your preferred slicing
software.
If not available in your slicing software, reduce via marlin and re-
flash.
Add small foam cushions below your printer feet to help disperse
vibrations.
Reduce weight on carriage if possible.
Have dampening for your axis if possible.
These problems are less of an issue on CoreXY and Delta machines.
Hotend Can’t Reach or Maintain
Temperature
This problem can arise in a couple different fashions. Your printer may be
able to reach its set point but then cannot hold it during the middle of the
print, or your hotend may not ever be able to reach the temperature you give
it.
Confirm you are using the proper wattage
heater
I had a consistent issue on one machine where it had extreme difficulty
holding 230°C, and could never reach 250°C. I had done all of the tests
mentioned below but the hotend just couldn’t make it. It turned out I was
using a 30W heater instead of 40W, which the machine was rated for
(Lulzbot TAZ 5 in this example).
Replacing the heater with the proper wattage fixed this problem
instantaneously. Wiring for the heaters is typically color coded by wattage,
so make sure the colors match and the rating on the cartridge are the same
when changing out your heater. You can check the resistance on the heater
to determine if everythign is correct. 12V 40W should be around 3-4 Ohms,
24V 40W should be around 14-15 Ohms.
Check firmware for MAXTEMP
It is also smart to confirm that the maximum temperature for your extruder
is set higher than you will be printing in your firmware. Your printer will be
restricted from reaching any temperature higher than this.

This should be automatically set to a safe number for your machine and
hotend, but if it was ever turned to 230, you would not be able to reach any
temperatures above that. If you were to upgrade to a high temp hotend, you
would likely need to tweak this number to what the new hotend is rated for.
Don’t set this to a high number if you are unsure of your hotend setup.
PID autotuning
PID refers to a proportional integral derivative controller that is used in 3D
printing to control the temperature of the nozzle. When the PID settings are
not correct, a fan can drastically change the temperature of the hotend.
An active cooling fan, or even something as minimal as the barrel fan, can
drop a hotend from 210°C to 160°C if the PID settings are off.
This rapid cooling will make the nozzle too cold for the filament to feed, or
may even prevent your print from starting at all.
If you notice that the temperature is fluctuating consistently around the set
point that is also a sign that the PID settings need to be tuned. Erratic
fluctuation is more likely to be a sign of intermittent electrical failure or the
temperature sensor getting lodged from its cavity.
You can change your overall PID settings for your machine in your
firmware, but I actually suggest getting a specific PID number for the
particular material and fan settings you are attempting to print. You can then
add these PID numbers into your start G-code.
I actually don’t really do this anymore since the machines I am using now
are able to maintain most temperatures without unique PID settings, but it
may be needed on your printer.
The first thing you will want to do is to mimic the material you will be
printing with (or at least the material you are having difficulty with). If you
will be using an active cooling fan, manually turn it on.
While still cold, you will then want to give this command through your
printer terminal (Repetier, Octoprint, etc.)
M303 E0 Stemperature
So if you are testing out PLA, and you want to print the PLA at 200°C, you
would type in:
M303 E0 S200
This will run a PID Autotune. After a decent amount of time your program
will feedback values for P I and D:

As mentioned in that readout, you would open up marlin and go to your

configuration.h tab in order to change the PID settings for your entire
machine.

Some machines
also let you change this within the EEPROM of the LCD screen. Just make
sure you store settings if you go this route.
You can also change the PID settings using G-code commands, which I
explain shortly.
As mentioned earlier, I actually suggest getting a separate PID value for
each material you plan on using for the most precise results, if this issue is
becoming a nuisance. This is because the numbers you are inputting may be
drastically different when printing at 200°C without an active cooling fan
vs. printing 250°C with an active cooling fan. This is particularly true with
lower end machines and may not be needed on well-built printers.
If you would like a specific PID setting for a specific material, run the exact
same M303 code mentioned above in the settings desired. For example, if
you would like to get a good PID number for PETG, turn on your active
cooling fan and run
M303 E0 S250
Once you are read out a number go to the start G-code section of your
slicing program. You will then want to add this line before your G90 input:
M301 H1 P##.## I##.## D##.##
Here is an example Start G-code for PLA with an active cooling fan I was
read out for one of my machines. Remember that each machine will vary:
 You would then
save this .ini profile so that whenever you are printing with this material in
the future, you will not experience dropping or difficulty maintaining the
nozzle temperature.
The final way you can set your PID is by using Repetier Host, Octoprint, or
another way you can give direct G-code commands to your printer (just as
you did when you tested for PID). You would then type “M301 H1 P###
I#### D####”. You would then need to type “M500” as to save those
settings. You can then type “M503” to confirm the settings have saved.
If your PID Autotune has failed, and you have confirmed you are using the
correct wattage heater, you can try the next solution
Get a new heater
This normally isn’t needed, but I have had a printer shipped to me that just
couldn’t maintain its temperature straight from the manufacturer. I ran PID
autotune a dozen times and still the temperature fluctuated all over the time.
Well it ends up it was just a malfunctioning heater. Replacing the heater
fixed the issue instantaneously.
Readjust or reprint active cooling fan
The most common culprit for hotend temperatures dropping mid-print is
that your active cooling fan kicks on and it is blowing directly onto your
nozzle. With your hotend at room temperature, turn on your active cooling
fan. Then place your finger onto your nozzle and hotend and see if you feel
a lot of cool air. If you are, this air may be what is dropping your hotend
temperature during your print.
You may be able to overcome this differential by running your PID tuning
while the active cooling fan is on, as mentioned above, but it doesn’t always
work. The best active cooling fans are ones that go around your hotend and
blow directly downward. You only want the air to be blowing onto your
print and not onto your nozzle.
If your active cooling fan is blowing directly onto your hotend, you will
need to print a new duct. Search on Thingiverse and elsewhere for a file that
will fit your extruder/hotend setup. There are likely dozens already created.
Make sure that this duct angles the air downward as to avoid the heater
block and nozzle.
These fan ducts can get in the way of your printer finding home, or can
even get in the way of raised bed clips, so be careful and confirm your
machine can move to all areas of your build plate before starting a print.
Add a silicone sock

As mentioned in a couple chapters in this book,

you should add a silicone sleeve to your heater block/nozzle, if the
manufacturer makes one. Not only does this silicone sock prevent burnt
black spots on your print, it can actually help insulate the hotend. Any air
blowing around the heater block will not have as much effect on cooling a
nozzle that has a silicone sleeve around it.
If you have confirmed you are using the proper wattage heater, that your
machine can reach the temperature you are trying to reach, air is not
blowing onto your heater block, you’ve added a silicone sleeve, and your
PID Autotuning is still failing, you will likely need to replace and re-flash.
Buy a new heater and thermistor, rewire to your board, and flash your
machine again. Then attempt to run the PID Autotuning code.
If still failing you may actually require a new board or power supply. There
is a problem that exists with the CR-10 boards where it has difficulty
holding temperatures of 230 degrees and above. TH3D Studios can fix this
easily over at TH3DStudio.com. I don’t claim to be an expert on why this
board was faulty, which is why a company like TH3D is great to use.
This is precisely what happened with my CR-10 and Timothy at TH3D
helped fixed it for me quickly.
Summary of Fixes and Precautions
Confirm you are using the proper wattage heater for your machine.
Check that you’re not exceeding the MAXTEMP for your firmware.
Run the PID Autotune sequence for the temperature you are having
difficulty holding, along with turning on any fans that will be
running during the print.
Change the PID in marlin to set the standard for your machine, add
the code to your start G-code for each given profile, or just set via
G-code commands.
Make sure your active cooling fan isn’t blowing directly onto your
heater block and nozzle. If it is, you will need to adjust it or reprint a
new fan duct so that it aims directly onto your print.
Add a silicone sock if available.
If all else fails, replace heater and thermistor.
Flash firmware.
Absolute final solutions would include replacing your board and
power supply, but this should not be necessary in the vast majority
of times you experience this problem.
CR-10 printers have this issue on some boards and it can be fixed
via TH3DStudio.com
Hotend Not Heating
This failure is not common but easy to diagnose, since your extruder will
not heat up. If the temperature is reading out properly, then this is an issue
with your heater. Many of these instructions are similar to the ones in the
“Build Plate Not Heating” chapter in this book.
After you confirm you are using the correct Volt/Amp for your heater/board
combination, you can move forward to checking the following issues.
Heater malfunctioning
The heater is the cartridge attached to thick wires (normally red or blue)
that is connected to the heat block of your hotend. As with all parts on a
printer, this cord can wear out and malfunction. Luckily, replacement
heaters are fairly inexpensive.
It is best to have a spare heater available so that you can easily test if it is
your heater or your board that is malfunctioning. All you would need to do
is to disconnect the heater from the board and connect your replacement
heater, and then see if heats up without any issue. If it does, then it may not
be worth your time to even figure out what is wrong with your old heater.
This is why it is great to have all of your important parts use a connector.
This way you do not have to cut wires if you just want to test a part out.
If you do not have a spare heater, you can start by checking the continuity
of the wires from the cartridge to the board using a multimeter. This may be
difficult for you if you do not have any connectors or exposed wires that
you can access near the cartridge, which is why I suggest testing by using a
spare. Even if you do find that one of the wires has a break in it, you will
likely need a replacement cord, since it needs to be a thick gauged wire. For
a 12V 30A heater, you will want at least a 14 gauge wire.
DO NOT REPLACE A HEATER CORD WITH A NORMAL SMALL
GAUGED WIRE (thinner than 18 gauge) YOU WILL BE SUSCEPTIBLE
TO A FIRE AND FURTHER BURNT OUT WIRES
Burnt out and/or disconnected wires and
connectors
This is far more common if you are experiencing issues with your build
plate not heating, but can occur with your extruder heater as well. You
should easily be able to see any burnt out connectors on your board with the
naked eye, and if you can’t, you will be able to once you disconnect the
hotend from the board.
When a connector or wire is burnt out you will not get any heating out of
your hotend, unlike what I describe in the next section. If there is a wire you
can easily see was burnt out in one section, you can often fix this without
replacing the entire wire.
A disconnect may be as simple as noticing that a connector had vibrated
loose. When there is a partial or intermittent break in the wiring, typically
referred to as fraying, this issue can be much more difficult to diagnose.
This should only ever be an issue on older machines with many printing
hours, and on machines where the wires aren’t organized. When this does
happen, try to replace the entire wiring harness with a new one if available
from the manufacturer. When one section of wiring begins to fray the rest
typically will follow shortly thereafter. Make sure to rewire in an organized
fashion.
With the printer off and unplugged, cut off the burnt section out of the wire,
and then solder the two sections that are not burnt out back together (or use
solder seal connectors). Be sure to use the proper shrink wrap because
absolutely no metal can be exposed after this process. I mention what I use
in the “Important Accessories and Replacements” chapter. Then you will
need to confirm that the extruder can reach its farthest point from the board,
because you just made the wire shorter than it was.
If your newly soldered wire cannot reach the board at the extruder’s furthest
point, you will experience layer shifts on large builds.
If you see that the connector going from your hotend heater to the board is
burnt out, you will need to replace it.
This is extremely common on the power input for RAMPS boards, and is
referred to as a design flaw. The connector that comes with the board is
easily overheated and can melt, which is exactly what happened to me on a
printer that I built. Since I had no active cooling fan, if I didn’t notice it
early, I could have had a real issue on my hands.
Historically RepRap boards don’t use connectors that are rated high enough.
If you are using a RAMPS board, I can’t suggest enough that you upgrade
the board terminals to a well-made 16A replacement (which can be found at
Digikey or Mouser). Make sure to refer to the “Electrical Safety” chapter
for more information.
Remember that the area you are replacing may have some melted plastic, so
you will need to clean it out entirely before attempting to reconnect. If
replacing the connector does not fix this burnt out area, you may actually
need to replace the entire board.
Only after everything is wired properly and there is no exposed metal, plug
everything back on and test to confirm the hotend is heating again.
RAMPS boards are actually quite out of date now and MKS or SKR boards
are now the standard Popular boards include: MKS GenL, MKS SGEN L,
and SKR V1.3.
Board overheating
Just as with the section above, this is more common with the build plate not
heating, but you will normally notice this issue if your heater starts to heat
and then cuts out at a certain point.
Remember that this is different than your printer not being able to maintain
a specific temperature, which I go over in the “Hotend Can’t Reach or
Maintain a Temperature” chapter. Rather, this will occur when your hotend
is heating up just fine and then entirely cuts out, going all the way back to
room temperature.
Not only will this cause a failed print, it will likely cause a severe nozzle
clog if your printer continues to try and cold extrude.
You can normally tell if this is happening by checking the temperature of
your board when the heater cuts out. Be careful though, because if the board
is overheating, it will be hot enough to burn your fingers.
I go over a few of these methods elsewhere in this book, but if you are
experiencing a board that is overheating, you will need to get 1-3 active
fans blowing right onto it. If your board is enclosed with the rest of the
machine, the build plate heating will drastically affect the ambient air
temperature, causing much more frequent times your board can overheat.
Small heat sinks will always help affected areas, but from what I can tell,
setting up some active fans make the biggest difference. Whenever using
active cooling fans, make sure to keep them well maintained. Check for
dust accumulation and make sure the area around them is free of debris (use
a filter/grill if possible to protect the fan blades). Broken fan blades can add
a lot of noise to your system and if the cooling fan fails, your board will end
up overheating again.
If your board is constantly overheating, or you are using a RAMPS board
with thousands of hours of printing on it, you will want to replace it
entirely. RAMPS boards are normally extremely cheap at under $10, but
higher end boards such as a Rambo board may be closer to $150. These
higher end boards will experience less overheating when wired correctly.

Summary of Fixes and Precautions

Confirm you are using the correct Volt/Amp for your Heater/Board.
Check for visual damage (burnt out cords/connectors).
Test out a new heater if you do not see anything noticeable.
Solder wires or rewire any section that is not connected or burnt out
- always using the proper gauge.
Replace any burnt out connector to the board.
Actively cool your board.
Replace board if overused or burnt out.
Hotend Not Reading Correct
Temperature
This failures refers to your hotend being a different temperature than what it
actually is due to issues with your thermistor, and can lead to bigger
problems if not properly addressed. This is noticeable when filament feeds
at different temperatures than it is supposed to, or if you are receiving a
message of “Error Min Temp”.
These instructions are similar to the “Build Plate Not Reading Correct
Temperature” chapter.
Error Min Temp (or Error Stopped Temp
Sensor)

If your thermistor
is not connected properly your printer, it will stop working and read “Error
Min Temp”. This is most common on fragile, non-cartridge thermistors, but
can happen on just about any setup.
If your printer is reading this error you will need a new thermistor the
majority of the time. You can order replacement thermistors from your
hotend manufacturer. I personally use E3D hotends, and you can easily
order replacement cartridge thermistors from their website, or from
Filastruder.com or Matterhackers.com for US orders.
You can measure your thermistors resistance to see if it is working correctly
as well. It should be 80-100K resistance depending on your room
temperature.
If your thermistor has no physical damage that you can see, you may be
able to fix this without buying a new one. This is when there is an easily
recognizable break in the wire, or if you can diagnose that there is no
continuity.
If there is a frayed wire or a section of a wire you can diagnose has no
continuity, you can cut and solder the wire skipping this section - or rewire
entirely. If your thermistor is still intact, replacing the wiring will likely fix
your issue. You will then you will need to confirm that the extruder can
reach its farthest point from the board, because you just made the wire
shorter than it was.
If your newly soldered wire cannot reach the board at the extruder’s farthest
point, you will experience layer shifts on large builds, or you can just rip the
thermistor off the hotend.
Other possibilities include your readout showing a negative temperature. I
have had this happened instead of an “Error Min Temp” when working with
the CR-10.
Not reading proper temperature
This issue is extremely difficult to diagnose if you are not looking for it and
when the differential is not extreme. When drastically different from the
actual heat you can have a major problem on your hand if the hotend does
not stop heating. If entirely not reading correctly, or if your thermistor is
hovering an inch next to your hotend, your printer will think that its hotend
is not able to reach its set temperature and will just continue heating it.
Many machines have safety settings to turn off your heater if it does not
reach its target temperature after a few minutes, but not all do. I have
personally seen melted metal from a heater block that never recognized it
was actually getting hot, since the thermistor was not connected to it.
Other less severe symptoms may include consistent nozzle clogs or
over/under extrusion. If you are only printing PLA you may not ever notice
the temperature is reading incorrectly, due to the fact most PLA has such a
wide extrusion temperature range.
If you have a device on hand that can read temperatures back to you up to
200°, then you can obviously use this to test the accuracy of your
thermistor. If you don’t, and you aren’t experiencing issues, a simple way to
test this is to try and extrude another material that has a small extrusion
temperature range.
Using a material that has a smaller temperature range of let’s say 220°C -
240°C will allow you to notice this problem a bit easier than with PLA.
MAKE SURE you are using a spool that is reliable and has no moisture in
it. Set your hotend to 220°C in this example, and if you cannot extrude any
of the material, it is likely that your thermistor is reading hotter than it
actually is. Do the opposite test if your hotend seems to be heating too high,
by attempting to feed the filament at 240°C. If the material crystalizes,
bubbles, clogs easily, or comes out extremely burnt, your thermistor is
likely reading a lower temperature than your hotend actually is.
For this issue you will want to confirm that the thermistor is properly
connected to the hotend. If the thermistor is hovering right next to the
hotend, and not inside its holder, it will likely read out a temperature lower
than the hotend actually is.
If connected properly, and there are no breaks in your wire, you will likely
have to replace the thermistor by purchasing a new one, as mentioned
above. This is why having a spare on hand is very beneficial
If none of these fix your problem, there is a small chance that your board
itself is malfunctioning and needs replacement. Flash your firmware to
factory settings, and if that doesn’t work, replace the board
Summary of Fixes and Precautions
Keep a spare thermistor for your hotend on hand if possible. I have
gone through dozens and dozens of thermistors over the years.
Make sure the thermistor is actually connected to the hotend. If
hovering next to it your hotend may not stop heating and can cause
serious problems.
If thermistor is noticeably damaged, replace it.
Check for breaks of frays in your wire and solder or rewire as
needed.
Make sure that if you do rewire you give enough slack to have the
extruder move to its farthest point.
Check that your hotend is reading the proper temperature by
extruding a low temperature range material at its low and high
temperature ranges.
Replace and rewire thermistor from the hotend all the way to the
board if all else fails.
Flash firmware to factory settings.
If still not reading proper temperature, you may need to replace your
board. Make sure you try replacing the thermistor before going this
route.
Important Accessories and
Replacements
You should always have a few accessories and replacements on hand so that
you do not need to order parts every time something breaks down. Some of
these tools I use every single day, while others are needed a lot less
frequently.
You can visit 3DPrintGeneral.com for more parts that I suggest and have
personally used, with direct links on how to buy them.
Accessories:
I consider all tools that are frequently used on 3D printed parts and the
machine itself as a 3D printing accessory. I actually have a video similar to
this chapter titled “Mandatory Accessories for a 3D Printer” on my
YouTube channel if you wish to see more.
Pliers: I can’t think of anything more important to support removal than a
set of pliers. You will use these just about every time you print with
support.
Razor Blade: Something you need to be extremely careful with, but
cleaning up a print will always be easier with some razor blades. I use them
just about every time I print with a brim, and it also helps to clean off any
“hairy” residue and pop off support interface.
Model Cutters: These sharp, thin scissors are a lifesaver when it comes
to printing very thin parts. If you have a very thin part of your print that is
being held up via support material, just going at it with a set of pliers will
likely break that fragile area. Using model cutters will allow you to cut this
support material off without damaging your print.
Scraper: A scraper will come with just about any 3D printer you buy, but
it is smart to have one that you prefer. I like a very strong metal that comes
to a thin, flat front. I have tried out flimsy scrapers that will bend on
difficult parts, and thick scrapers that are difficult to get under your print
without damaging it. Get a strong metal scraper that tapers at the very front.
I like the set by AMX3D if you wanted a suggestion.
Metric Allen Screwdriver Set: Just about every printer on the market
uses a lot of Allen screws. Having an Allen wrench set is smart, but having
an Allen screwdriver set is even better. It can be difficult to get to some of
your screws via a normal Allen wrench, but is far easier with an Allen
screwdriver.
The most common size of screw used an M3, but it is smart to have an
M2.5, M3, M4, and M5 Allen screwdrivers. I don’t know of any 3D printers
that use standard sizes, almost all use metric. In order to make just about
any fixes or repairs to your printer, you will need this screwdrivers/wrench
set.
Solder Set or Solder Seal Wire Connectors: Wires become frayed,
and you will often need to cut them to attach new parts. There are plenty of
times in this book where I go over how to fix parts on your machine, and
most of them require to you cut and fix frayed wires.
The most common way to do this is to get wire strippers, solder, a soldering
iron, heat shrink, a heat gun, and maybe some tin. There are plenty of
tutorials on how to solder wires, which involve stripping the wire, adding
some tin to help solder stick, and then using your soldering iron to melt the
solder to the two exposed wires. This makes a strong connection which you
cover with some heat shrink so that no wires are exposed. I personally use a
wireless soldering iron by Iso-tip since I prefer it that way, but just about
any soldering iron would work.

I discovered
solder seal wire connectors about a year ago, which have become my new
favorite way to do this. With solder seal wire connectors you do not need
any soldering iron, solder, tin, or heat shrink – just wire strippers. These
connectors have solder in the middle where you push the two stripped wires
to. You then use a heat gun (or even a lighter if you are careful) to melt the
solder and shrink the wrap around the wires. I definitely suggest having a
set of these for when you need to connect wires if you do not want to pay
for a full soldering kit, or are just not good at soldering like myself.
You will still need a soldering iron and solder to connect wires directly to
parts, such as with a heated build plate, but these connectors work great
anytime I need to connect two wires.
You will actually want to make sure you buy the more expensive version of
these, with me suggesting the DX Engineering ones. These are more
expensive than others you may find on Amazon, but they are worth it.
Inexpensive ones will have solder that melts at too low of a temperature and
can add resistance to your printer. If you do not want to purchase the more
expensive version, you will likely want to just go with a standard soldering
iron kit. You can also purchase these at auto stores.
Zip Ties: Obviously zip ties are not ideal for important parts on your
machine, but they can definitely help out in a pinch. They can also help to
clean up your wires by zip tying them all together. I always have a large box
of different size zip ties on hand since I use them quite frequently, and never
know when I will actually need them.
Make sure you actually buy well-made zip ties by reading reviews first.
Calipers: Calipers help immensely to accurately measure parts and
filament. If you are doing any sort of designing, you are definitely going to
want calipers. They also help to properly figure out your E-steps.
Multimeter: A multimeter has a ton of features and uses, but I really just
use the continuity setting for the majority of my 3D printing needs. You can
check voltage, amperage, and much more, but just figuring out if a wire is
working properly is its best function.

You can easily

touch a metal tip to one side of your wire, and the other metal tip to the
other side, and you will be told if there is continuity with a beep. This can
help immensely when trying to diagnose what isn’t working on your printer,
as mentioned in many chapters.
Loctite Super Glue Gel: My personal favorite way to combine parts
strongly was actually Devcon plastic welding, but Loctite Super Glue gel is
the easiest to use. I believe this has become the favorite of most 3D printing
enthusiasts to combine plastic parts together. Keep in mind combining
different types of materials may require different adhesives, but Loctite
Super Glue Gel works wonders on PLA, and it dries extremely fast.
You will have to remove the outer container when running low, since there
is still about a quarter of the gel left in the tube after you are unable to get
any more out.
I have also used Starbond very recently though and they may be my new
favorite method. Starbond Thick is very similar to Loctite Super Glue Gel
and seems to hold just as well (if not better). Starbond also has an
accelerator spray that allows the glue to dry within a few seconds, meaning
you don’t need to hold parts together for very long.
I have yet to find a good way to glue two nylon parts together.
White Lithium Grease: There are different preferences when it comes
to lubing up important rods on your machine, but my favorite is white
lithium grease. Periodically lubing threaded and smooth rods on your
printer will help to get consistent clean prints.
Wire and Nylon Brushes: Nylon brushes are key to cleaning up a dirty
nozzle and heater block. The only issue is that the nylon may melt on hot
heaters. I really like to use brass brushes, but the added abrasion is not great
for the hotend. If you have a very dirty heater block and nozzle, go ahead
with a brass brush, but try to use nylon brushes when possible.
It can be quite difficult to clean up a dirty heater block and nozzle without a
set of these brushes.
Heatsinks: As mentioned in the “Stepper Motors Overheating or
Malfunctioning” chapter, it is very smart to have some heat sinks on any
parts that may be getting too hot. They help to disperse heat and are very
smart to add to the extruder, X, and Y stepper motors. Use with a thermal
transfer adhesive backing or paste to attach.
Something for organization: This is pretty vague, but keeping your
important accessories organized in a place near your machines will help a
lot. I personally have a strong magnetic bar by my machines that have all of
my tools attached to it. This way when I need something fast I can easily
grab an Allen key, pliers, tweezers, scraper, etc.
You could also use some small containers that are labeled, just make sure it
is all right next to your machine and organized so you don’t go crazy
looking for that part you need right now.
Fire Extinguishing Ball: It’s hard to say this is really a 3D printing
accessory, but it is something I can’t stress enough to have in case of
emergency. Hopefully it is never needed, and it will likely never be needed,
but if it is, you will be happy you had one.
I have read too many stories about someone’s printer catching fire,
sometimes bringing down the entire house. If you are using the proper
electronics on a well-built machine, it should never happen, but you want to
idiot-proof yourself for something this serious. I have an AFO Fire
Extinguishing ball mounted above my printers, and considering it will act as
insurance on your house, $40 is well worth it. Make sure to check out the
“Electrical Safety” chapter for more information.

Replacements:
While it is nice to have replacements for every part in your machine, this is
clearly not practical. Below are a list of inexpensive parts that should be
held on reserve in case you were to ever need them.
Thermistors: Thermistors essentially act as thermometers for your
hotend, making sure the heater goes to the proper temperature. These are
very fragile parts, and many heater blocks just hold them in via a small
screw and washer. These are very inexpensive and nice to have backups in
case you ever get an “ERR: MINTEMP” or negative temperature readout.
I have gone through dozens of thermistors over the years, and they cost less
than $5, so I definitely recommend a few spares for your hotend.
Heater: Heaters do not need to be replaced very often, but it is another
inexpensive part that may come in handy. It can help to save you time
diagnosing any hotend heating issues.
Nozzles: This is probably the most important replacement to have on hand.
Brass nozzles wear out quite easily, and even hardened steal ones will
eventually need to be replaced. If you are ever having difficulty diagnosing
why your prints are coming out ugly, it is well worth swapping out your
nozzle. Brass nozzles cost under $5 and hardened steel ones are closer to
$15, but you will be extremely happy once you change your nozzle and it
fixes your problems. I believe hardened steel versions are worth it, since
you will not need to swap nozzles nearly as often. Personally, I have
standardized to Nozzle X by E3D.
I have a video titled “The Importance of Replacing Nozzles” which goes
over this further if you wish to learn more.

It would also be
smart to have a few different nozzle diameters on hand. A good set would
be a couple 0.25mm, 0.4mm, and 0.6mm nozzles, and maybe a 0.8mm for
large prints.
Fans: Brushless fans can become damaged if accidentally hit when
spinning, and may just burn out over time. If this is your barrel cooling fan,
you are destined for repeated clogs. Make sure you have a couple of spare
fans on hand for when you need them. The majority of fans on a printer are
40mm x 40mm x 10mm, but some use different sizes. E3D setups use a
30mm x 30mm x 10mm fan on their barrel. Just make sure you purchase the
correct voltage for your machine.
Silicone Socks: These silicone sleeves go over your heater block and will
help to prevent black spots on your print and to maintain print temperature.
I definitely suggest to always print with these silicone socks, and to have a
couple backups. These will eventually degrade and break over hundreds of
hours of printing.
Teflon (PTFE) Tubing: Teflon tubing is used to help guide your
filament to the hotend. It helps to prevent filament tangling and to make
sure everything is guided correctly. Every so often these can be damaged
when pushed into your hotend, so having some extra tubing on hand would
be a smart idea.
Endstops: Endstops are another inexpensive part that will every so often
need replacement. This doesn’t necessarily need to be purchased before
needing it, but can save you a couple of days when you run into an issue.
Layer Shifts
Layer shifts refer to when the print looks fine other than the fact that one or
multiple layers are shifted in the X or Y direction. Layer shifts can be
something as simple as a loose wire or can be as difficult as recognizing
that your stepper motor pulley is not functioning properly.
This can result in a print that has one, or multiple layer shifts.
Single Layer Shift
This issue is normally a bit easier to diagnose and fix than a print with
multiple layer shifts.
Obstruction during print.
The most common cause of a single layer shift is that there was an
obstruction during the printing process. This can be from tangled or too
tightly wound filament, or from a cord that is the way of an axis from
moving properly. You will see this occur more frequently on larger prints
than small ones.
It is another reason I suggest only buying highly made filaments from
reputable manufacturers. I have actually had brand new filaments that had a
tangle in the middle of the spool, causing a layer shift mid print. I have
heard people say this is impossible – but it has definitely happened to me.
You will want to make sure that your printer has a clear path before starting
a print, and that all cords and wires are not in a position to obstruct after
moving throughout the entirety of your print area. Confirm your filament is
tight on its spool and that you maintain it in a way that will not allow it to
tangle. If you have a spool that is becoming unwound during the print, get
some Teflon tubing and mount it to your frame as tight as possible to help.
Zip tie all cords in a fashion that get them out of the way of the toolpath.
Anything in the way of the extruder or build plate that is stronger than your
stepper motor will cause a skip, and then result in at least a layer shift.
Endstops in wrong spot or frame not set
up properly
You will run into issues with a single layer shift if you are printing
something large and your full print area is not set up properly. If you are
using a slicing program where your machine settings are not to the proper
dimensions of your printer, the machine will think that it can print further
than it actually can. The stepper will skip when your extruder or bed hits its
max build area, and the print will continue, assuming that it went the entire
tool path.
You can check to make sure everything is set up correctly by homing your
machine. When you home the printer and it goes to the very corner of your
build plate, you likely have everything set up properly (or the center for
printers with a home at center).
When you home the machine, if there is accessible print area in front of or
to the side of the build plate (depending on your homing setup), you are not
going to be able to use the entirety of your build area.
This can easily be fixed if your X or Y endstop is just in the wrong position
by slightly adjusting their location. If these endstops are fixed on your
machine, the frame itself may not be set properly. Adjust any t-nuts that
may be holding your bed in the position it is in and slide until in the proper
homing position. Retighten and make sure nothing can rattle. You need to
make sure that your printer homes in the correct spot in order to take
advantage of the entire build area. You would never know there is an issue
on small prints until you decide to go with a large G-code.
Errors in G-code or model
You will want to check out the “Model Errors” chapter for a further
description, but essentially files can be corrupted or exported improperly.
While in your slicing program check the model layer by layer to see if there
are any holes or missing walls. Also be sure to check for actual errors on
software such as Cura or the old version Netfabb.
Your G-code can actually be corrupted as well. This is not common but I
have had prints that just would not print properly no matter what I did. This
normally happens if you transfer a file before it has completely saved.
This is a lot harder to diagnose, but if you have a part that has caused a
layer shift in the exact same spot after reprinting, then it is worth your time
to reslice and reupload to your machine. It would be very unlikely to
experience a layer shift in the same position if it were just caused by an
obstruction.
Too thick of layer heights - turn combing
off/use lines for infill
This should not be an issue when working with standard nozzle sizes and
layer heights, but can become an issue when going over 0.4mm layer
heights. When I tested out the SuperVolcano with a 1.4mm nozzle and 1mm
layer heights, my nozzle would drag over the previously laid infill when
traveling.
Turning off combing allowed for the hotend to z-hop after every movement
and avoid this infill. I also switched from triangular infill to lines, in order
to avoid the same problem. When I did not do this – I got a layer shift from
the nozzle hitting the infill and skipping the stepper motor.
Multiple Layer Shifts

Belts too
loose (or too tight)
Belt harnesses on many machines are built in a way that will cause
loosening over frequent printing. Some inexpensive machine harnesses only
hold the belt tight via a zip-tie.
A loose belt will cause slippage and excess play. This is a very common
problem when you are using a heavy bed that moves back and forth
frequently (you will see frequent layer shifts in the Y-axis).
You will want to make sure your X and Y carriage have belts that are very
tight. You can actually over tighten them, but from my experience, a loose
belt is far more common than one that is overly tight. If your belt is too
tight it may cause binding and ghosting (as covered in that chapter).
It is smart to print an adjustable belt tensioner for your carriages. This will
allow for easy tightening when things get lose over time – otherwise you
will likely have to disassemble. I go over this further in the “Z-Wobble”
chapter. After adding one of these you actually can over-tighten, so be
careful.

There is no specific measurement to judge if your belts are properly tight, I

usually just say you don’t want any droop and want the belt to be springy to
the touch. If the belt feels as though it’s stretching and has no real give –
you’ve gone too tight.
Bed corners tightened to their max
This is actually far more common than you would think. When attempting
to get a level build plate you may run into a time that you end up over-
tightening one or multiple corners. You do not want these corners at their
maximum spring tightness because over time it can actually warp the metal
plate. These warps will make your problems even worse.
You will notice an issue when you try to move the Y carriage (on Cartesian
setups) with the printer off and stepper motors disabled. When one or
multiple corners are over tightened, the bed will be difficult to move.
I suggest starting fresh by loosening all of the corners until they have equal
minor tension on the springs. If you now notice a big difference in how
easily your bed moves, then this is likely the culprit. Get the Z-rods even by
checking the distance differences for the nozzle to the bed in the X
direction. Just hold one rod in place while you twist the other, leveling the
X-carriage (as explained further in the “Unlevelled Bed” chapter).
Only then should you adjust the corners for a level build plate. If you have a
very warped metal plate you can experience certain corners that will just not
get level no matter what you do. In this instance you will actually need a
new metal plate. This is why you do not want to leave any corner over-
tightened for long periods of time. You will be slowly putting pressure on
an item that may get bent over time. Using a thicker ¼”glass build plate
helps to make this issue less common.
This is just one of the many reasons an auto bed levelling device (such as
the EZABL by TH3D) may be worth your time.
Dry rods or broken bearings
Most printers have self-lubricating bearings for their carriages, but even
those can get dry over frequent machine use. If you are having difficulty
manually moving the X or Y axis when the machine is not printing and
stepper motors are disabled, check to see if the rods are extremely dry or if
the bearings are broken. A broken bearing is easily replaced and a dry rod
can be fixed with some white lithium grease. Also check to make sure that
the rods themselves do not have scarring from the bearing wearing down. If
the rod is heavily scratched, then that may need to be replaced as well.
Just rub a minor amount of white lithium grease to the rods (both threaded
and smooth) and then move the carriages around so that it spreads. If you
notice a drastic increase in smooth movement of your axes, then you may
have fixed your issues of multiple layer shifts. I have actually noticed some
big difference and reduction in layer shifts after doing this in the past on
machines with thousands of hours of run time.
Reapplying lithium grease and checking the resistance on the rods/bearings
is good practice regardless of experiencing layer shifts, since it can help to
allow for consistent clean prints.
Bent rods
Rods, especially thin threaded 5mm Z-rods, can become bent over time.
This bent rod can cause one or multiple layer shifts as the carriage or bed
travel over these bends.
If you notice any rods that are bent, replace them immediately.
Level Build Plate

If one side of
your X-axis is much higher than the other, your printer may have difficulty
evenly moving the extruder. Having one side of your machine be unleveled
from the other could end up causing your stepper to skip multiple times,
leading to many annoying layer shifts. This will also put unnecessary
pressure on your rods which may cause them to bend and need to be
replaced. Make sure took keep your X-axis level.
The same thing is true with the build plate. If it is angled and the rods aren’t
straight, the build plate won’t move freely, and can cause multiple layer
shifts.
You will notice that moving your carriage with steppers disabled will be
hard if the rods aren’t straight. You want to make sure that the bed and
carriage can move very easily when steppers are disabled.
Acceleration or speeds too high
Your motor’s torque at a given speed must be greater than the force needed
to accelerate or decelerate the carriage at a given acceleration rate and
maximum speed. If you require a higher torque than the motor can supply at
that given speed or acceleration, the layers will shift via the motor skipping
(similar to how it is explained in the “Extruder Motor Skipping” chapter).
You can decrease the speed in your slicer settings, or by manually turning
down the knob on your LCD screen. Acceleration can be decreased on the
LCD screen as well, but to permanently change it you will want to go into
your firmware. You can also just change the acceleration right in your Cura
slicing. You will see this in the “Speed” section of Cura, as explained in the
“Settings” chapter.
As mentioned in the “Extruder Stepper Skipping” chapter, you likely do not
want this number over 1000, and for some machines you won’t want this
over 500. Manually reduce this number and see if it helps. I actually have
my machine set to 500m/s/s acceleration even though it can likely handle
higher, since I want consistently good quality, non-ghosted prints and am
willing to wait the extra time required. CoreXY machines can handle a
higher acceleration than Cartesian.
If you do not have an LCD screen, it is not offered in the slicing program
you are using, or you would like to permanently change this number, you
can find the acceleration in your printer’s firmware in Marlin under the
Configuration.h tab.

You can also find these numbers via a G-code command through Repetier
Host, Octoprint, or another terminal you are using. You will be fed out the
current numbers if you type in the command “M503”.
You can then set each of the numbers via their relevant G-code commands,
and type another M500 to save the settings.
If you are ever having extreme difficulty with a printer and want to flash
back to factory settings, but you do not have the version of Marlin for your
printer, you can also type “M502”, which is a factory reset. Remember you
will lose any settings you may have changed (such as E-Steps), but this has
saved me in the past when I was unable to determine why my motors were
performing improperly.

Driver current is too low or too high

Having the current going to your stepper drivers too low can cause
insufficient motor torque and result in layer shifts/stepper skips. A driver
current that is too high may overheat the stepper and cause a thermal
shutdown. This shutdown will result in that stepper no longer working until
it is cool once again. The same is true if the driver on your board is too hot.
Make sure that you have a fan on your board, a heat sink on your stepper
motor, and a small heat sink for your stepper drivers. You can then check
the current via the method described in the “Extruder Stepper Skipping”
chapter, but with the X or Y motor in question. This should not be an issue
with factory made machines, but will be more common on the inexpensive
DIY ones, though I have had to change the stepper driver on one machine
that was experiencing this overheating issue.
Remember to try previous methods before moving forward. This is only if
you can tell your motor does not have enough power going to it. You may
even want to test swapping the motor itself before to see if it is the motor
itself that is faulty.
You first want to have your machine turned off and disconnect the stepper
motor cable from the board. You then need to look up both the stepper
motor you are using, as well as the stepper driver.
Current limits are determined in the motor and driver data sheet. You will
not want to run higher than either the driver continuous current limit, or the
motor current rating limit, so it is often good to have a driver that has a
higher continuous current rating. I suggest going off of the continuous
current limit of the Motor.
Once you know what current limit you want, you then need to find out the
calculation for your stepper driver to determine a Vref. I had always
assumed the calculations are the same, but they definitely are not. You can
go to the current limiting section of your stepper driver data sheet in order
to figure out the VREF you will want. Current limit will equal Vref x 2.5
for standard A4988, and Vref x 2 for DRV8825. There is then another
option by TMC where the calculation is slightly different, where Vref=
(Motor current x 2.5)/1.77. To find out your ideal Vref, there is a handy
calculator that someone made online which you can search for by typing
“Stepper Driver Vref Calculator”, where you just enter the rated current of
your motor and it will read out the ideal Vref numbers for each driver type.
I understand this is very confusing for someone who is new to this, just as it
was for me. But essentially the Vref is the power that is being sent to your
motors and it can be tweaked depending on your motor and stepper driver
setup. So if your max current limit on your motor is 1AMP, and you are
using the standard A4988 driver, you will have a Vref of roughly 0.4. This
is because 0.4 x 2.5 = 1. This 0.4 would be your target number that your
multimeter will read out. If your Vref is lower than 0.4, you will not be
having enough power sent to the motors, meaning they can result in layer
shifts and motor skips. Going higher than 0.4 can result in an overheated
motor.
To test this out, you will actually need to plug back in your power and turn
the machine on, while you still have access to the board. Be careful now
that everything is on. Make sure the driver you are testing has the stepper
motor unplugged from the board. You would then grab your multimeter. No
real way to do this without a multimeter.
Set your multimeter to 20V DC, and touch your black negative lead to a
ground pin on the stepper driver (titled GND). If you are unaware which the
ground pin is, you can also touch the black negative lead to the negative
section of your power supply. Just make sure to only touch a ground
section.
You can then clip the positive lead of your meter to the metal shaft on the
screwdriver to help read everything out while you change it. If you do not
have a clip to connect the lead to the screwdriver, you will need to test,
tweak, and test again. You then touch the positive lead (or the screwdriver if
you have it clipped) to the potentiometer on the stepper driver. This is a
very tiny screw like object on the driver. You will then see a voltage number
on your multimeter. This is your Vref, which you want to make sure equals
your calculation above.
You can turn the screwdriver clockwise to increase the voltage, and
counterclockwise to decrease (which is actually the opposite on the TMC
driver, so just make sure you are testing after each small turn). A 1/8 turn of
the potentiometer will make a drastic difference in your Vref – so make sure
to not turn too fast.
Remember, this shouldn’t really be necessary on factory made, high end
machines, since everything should be set to the proper ratings stock. But if
you are experiencing layer shifts from skipping X and Y motors, it is
definitely worth checking out.
Stepper still skips
If your stepper still skips, you may have a malfunctioning motor or have
wiring issues. Check the connectivity for each wire going from your stepper
to your board. If there is a break somewhere you will have to replace it or
cut it and rewire.
The stepper or driver itself may be malfunctioning, so try switching the
connectivity to a different axis and see if the motor still skips when moving
that axis. If it does, replace the stepper to fix your layer shifting and
skipping issues.
It also may be worth re-flashing your firmware or going back to factory
settings if this issue came out of nowhere.
Cheap or worn-out pulleys
Pulleys for your motors need to have sharp defined teeth with the proper
spacing in order to work properly moving your belt the correct amount of
steps. They also need to be tight on the stepper motor shaft, since any
slippage on this will cause a layer shift.
If you buy a poorly made pulley, or notice that yours have had the grooves
worn down, you will want to upgrade and purchase a new set. Go for
products made from aluminum or stainless steel made products, since small
items such as this are not that much more expensive, and can make a huge
difference.
Make sure the small inserts on this pulley are tight to the motor shaft, with
one of the inserts pushing against the flat part of the shaft, making sure it
can’t spin freely at all.
Bed too heavy
This normally is not an issue if you have your drivers putting out the proper
current and everything is lubed, but if you have an abnormally heavy bed
you may experience shifts in the Y-Axis (on Cartesian machines, this should
not happen at all on a CoreXY machine.). If you are trying out an
experimental bed with a lot of wiring and extras on top of a ¼” thick glass
bed, this axis may have difficulty moving without experiencing some layer
shifts.
Running into the print
A less common problem with layer shifting can be when the printer head
runs into the layer it just printed. This can cause a skip in the motor and will
have the print continue where it left off. You are more likely to get a print
knocked off the build plate in this occurrence, but sometimes it can cause a
layer shift.
This is most common when you are over extruding at very low or very high
layer heights with a very strong bed adhesion.
As explained in the “Parts Being Knocked Over” chapter, you will want to
add a Z-hop to that of your layer height, that your hotend is assembled tight
and not oozing, and you will want to make sure you have your printer head
avoid printed parts in your slicer settings.
Z-wobble

Some may
consider Z-wobble in the class of layer shifts, but I have it as its own
category. If you are experiencing a wobbly looking print in the Z-Axis
(never ending extremely small layer shifts), please refer to the “Z- Axis
Wobble” chapter

Summary of Fixes and Precautions

Clear the printing path of your carriages from any obstructions. –
Zip tie all wires and loose cords, and maintain a clean printing area.
Confirm end stops are in the correct spots and that the frame is built
correctly so that when you home the nozzle it is in the furthest part
of the corner that it can be.
Check for errors in model or reslice if G-code is corrupted.
Increase z-hop, turn off combing, use lines for infill to prevent
nozzle from hitting the print on large layer heights.
Make sure belts are tight enough (but not too tight).
Do not over tighten bed corners.
Make sure the rods are not dry or that any bearings are broken.
Replace any bent rods.
Reduce your acceleration and/or speed.
Increase or decrease the current going to your stepper drivers (if you
are confident the stepper is underpowered).
Check to see if your stepper or drivers are malfunctioning or
overheating.
Make sure your pulleys are attached tight to your stepper motor shaft
and cannot spin freely.
Replace or upgrade your pulleys.
LCD Blank or Dark
If your LCD goes out there are really only a couple of solutions available.
Most of the time you can still print with a blank LCD screen, but you can
no longer use an SD card to load G-code. If your LCD goes out and you
cannot control your printer by using a computer, it is likely your board
needs a new NANO fuse, or the screen itself has burnt out.
Replace NANO fuse
I am not familiar with every board on the market, but Rambo boards use
two small NANO fuses. Companies such as LULZBOT use Rambo boards
on their TAZ machines.
These NANO fuses can become quite a nuisance because they do go out
more frequently than you would expect. When one of these fuses goes out it
can cause your LCD screen to go dark. You also will not be able to control
any axis or activate any heaters via Octoprint or Repetier when you are
have a blown NANO fuse.

When this first happened to me about

4 years ago, I had to call the manufacturer, because I went through all of the
procedures and could not get the LCD screen to work. I had not thought to
replace one of these small fuses. You can buy replacements on Digikey or
Mouser by searching for a 5A NANO fuse, such as ones made by Littlefuse.
The specific part number is 0448005.MR for this Rambo board, and they
are roughly $2 each. I highly recommend having extra on hand if you have
a board that uses these NANO fuses.
Be sure your machine is off and unplugged before working with these fuses.
Carefully remove one and replace it with one of these fuses you purchased.
I suggest using a set of tweezers. Re-plug your machine in and see if it fixes
your problem. If not, switch the second NANO fuse instead.
I believe every time my screen has gone out yet I could not control the
printer it was due to one of these NANO fuses blowing.
Check connections to LCD screen
If you can control your printer but your screen is out or dark, you will want
to check all the connections to your LCD screen. Confirm that nothing has
been disconnected from either the screen or the board and that there are no
breaks in the cords. I have not personally experienced this since the LCD
screen does not rattle around during the print, but I can only assume it to be
possible. Use your multimeter if required to check continuity.
Replace LCD screen
I understand this is not ideal, but LCD screens do burn out, especially on a
machine that is over a year old with frequent usage. Luckily, LCD screens
for basic RepRap machines will only be about $10, but ones for machines
such as a Lulzbot TAZ will be closer to $70.
Personally, I have only had to replace three LCD screens in my roughly 5
years of printing history. So while it is not common, it is definitely possible.
If you have a brand new machine, or one only a couple of months old, your
LCD screen should not be burnt out. If this is the case you may want to
check with the manufacturer if it is under warranty, or if they will replace
due to it being faulty.
Finally, as with many other solutions in this book, if your screen is still dark
you will want to re-flash the firmware, and then replace the board if all else
fails.
Replace the LCD cable
If you still can’t get the LCD to come back alive, it is very likely that the
issue is with the LCD cable. If you have another printer available, swap the
LCD screens and see if you can get it working. I’ve seen one case in which
the old screen lit right up when swapping it like this. In this case, the system
was back up and running with the original screen after replacing the cable.
Summary of Fixes and Precautions
Check to see if you can still control your printer when plugged into
your computer.
If you cannot control your machine, it is likely a Nano fuse was
blown. Replace one or both.
If you can control your machine, check to see if there are any breaks
in the wire to your LCD or if any connections are dislodged.
Replace the LCD screen if you do not see any problems with the
wiring.
Re-flash firmware, and finally, replace the board if all else fails.
Mandatory Maintenance for your 3D
Printer
The majority of the tips covered in this section are covered elsewhere for
specific issues, but these are all mandatory to do frequently to achieve
consistently clean prints. I will perform all of these once every couple of
months as precautionary steps to not have to worry about fixing a problem
after it occurs.
Most of these steps are also covered in depth in a video I made titled
“Mandatory Maintenance for your 3D Printer” on my 3D Print General
YouTube channel.
Check there is no gaps or rattling from the
bearings
Most machines have bearings that allow the X and Y axis to move along
their rods. These bearings are attached to your carriages normally via
printed parts. These are not present on a rail systems.
What you will want to do is grab your hotend when the machine is off and
try to rattle it around. There should be no movement via this rattling. If
there is, and you have made sure your hotend is setup properly, this rattling
may be coming from gaps in your bearings.
Many machines use plastic bearings that can actually be stretched over
time. Bearings should be gripping tight onto your metal rods, and if there is
any free play, it can result in ugly prints. I have had to replace plastic
bearings on all machines I have used with them after about 6 months of
consistent printing. It is very noticeable after switching to new bearings that
the rattling is entirely removed.
If you are using metal bearings, this is very unlikely to be the issue. That
said, you will want to make sure these bearings themselves are harnessed
tightly to your carriage. This may mean you will need to print new parts or
use new zip-ties, since the bearings should be held as tightly as possible to
your carriages.
This same exact process should be done for your printer bed, assuming you
have a Cartesian machine. In the video I made mentioned in the
introduction to this chapter, I had to replace all of the zip ties holding the
bearings to my build plate, since they stretched over time.
There are many printers on the market that do not use standard bearings, but
rather use rollers that move across an aluminum T-slot called in a rail type
system, and these are not only beneficial due to their sturdiness, but will
also not require any maintenance on bearings.
Tighten all belts
Other than confirming all harnesses are tight and that there is zero rattling
on the extruder and build plate, the next most common reason for Z-wobble
is a loose belt. Minor Z-wobble will not be extremely noticeable, so it is
important to do check this frequently to keep prints to their proper
dimensions.
As explained elsewhere in this book, it is possible to over tighten a belt, but
it is pretty difficult to do so on low end machines where the belt is just held
together via zip ties. Both the X and Y axis belts should be very springy to
the touch with zero droop. There is no real method to measure if your belts
are properly tight, you just want to make sure there is no droop and that the
belt isn’t being stretched. Somewhere in between those two is the ideal
range.
If there is any droop in your belt, you will need to tighten. For low end,
non-upgraded machines, cut the zip tie that is holding the belt together, grab
some pliers, and pull tight as you put on a new zip tie. Make sure the belt is
tighter than it was and that the zip tie is pinching everything so that the belt
won’t slip.
Even better than doing this would be to print a manual way to tighten your
belts. There is likely a file on Thingiverse for your specific machine setup,
you would just need to search. I have added such a way to tighten the X-
axis belt on my CR-10 by a model designed by donnyb99 on that site. I
disassembled the X-axis belt and where the bearing is connected, and then
added this printed part. I can now easily tighten the X-axis belt via a simple
turn on the knob.
Be careful when adding one of these, since you will now be able to over
tighten, which I had mentioned is difficult to do without this. Just turn the
knob until the belt is very springy to the touch. There is no real scientific
way to do this, you just want to make sure there is zero droop whatsoever.
Clean up wiring
Just because you aren’t experiencing an issue doesn’t mean you shouldn’t
keep your wiring neat. Tangled wires from disorganization can lead to
potential layer shifts or ripped out wires. If your barrel cooling fan’s wires
are ripped out mid print, you will get a nozzle clog – one that could have
been prevented if you made sure your wiring was organized.
Make sure everything is tucked away and that there is no chance for any
wire to get snagged mid print.
Replace nozzle (especially if brass)

Above is a photo
from a print with a worn out nozzle next to a brand new one.
As mentioned elsewhere, hardened steel nozzles do not need to be replaced
nearly as often as brass ones, but replacing to a new nozzle can never hurt. I
would replace brass nozzles just about every month or two to ensure that I
don’t run into any issues in the future, but I have since upgraded to only
using hardened steel nozzles. As discussed in the “Over/Under Extrusion”
chapter, even hardened steel nozzles can be worn out over time leading to
very ugly prints even with all the proper slicer settings.
I can’t tell you how many times I have gone crazy trying to figure out why
my prints were coming out ugly only to replace the nozzle and have my
problems disappear.
Refer to my video titled “The Importance of Replacing Nozzles” on my
YouTube channel for further information and comparison images of before
and after.
Check E-Steps
This is the exact same process covered in the “Over/Under Extrusion”
chapter, but you shouldn’t wait until you see a problem before checking.
Once every month or so I will check my E-steps to make sure they are on
point, and will tweak if necessary. I don’t wait until I see an under or over
extruded part since I would rather prevent the problem before it happens.
For most under and over extrusion issues, you will want to check and
calibrate your E-steps. To do this is actually quite simple.
You will want to start off by measuring out 100mm of filament. You can
actually measure out even more for a more precise readout – you will just
have to account for that in the calculations below. I prefer to use White PLA
because it is the easiest to write on, has a low printing temperature, and is
cheapest - though you could use any material you have at your disposal.
You can do this in whatever method is easiest for you. I found it easiest to
measure this 100mm when the filament is already fed into the extruder. You
can also do this on a desk before feeding, but 3.00mm filament, and 1.75
near the end of its spool, are quite hard to keep from rolling back up.
Be as precise as you can by using a fine tip sharpie and holding the material
as straight as possible. Use calipers if you have them at your disposal. After
heating your hotend, you then want to push the filament down until the
lowest dot you made lines up with the top of your extruder, or somewhere
else you can easily line up the starting point (because you will need to
compare it to where it finishes).
The next thing you will want to do is to tell your printer to extrude 100mm.
This is done with a simple G-code command in your terminal.
If you normally print via SD card you will need to hook up to a computer
for this. If you print via Octoprint or a similar online program, you can send
the G-code commands from their terminals.
When hooked up to Repetier Host, or whatever program you use to control
your machine, and with your hotend hot, you will want to give your
machine the command:
G92 E0
This sets your extruder to 0. Next you will want to give either the
command:
For 3.00mm Filament: G1 E100 F30
or
For 1.75mm Filament: G1 E100 F60
This will tell your extruder to feed 100mm, and is why it was important you
lined up your starting dot with either the top of your extruder or something
else that is easy for you to compare to.
Once your extruder has finished you will want to mark your filament at the
same spot you lined up your original dot (top of extruder in my examples).
If your 100mm dot lines up perfectly, then your E-steps are right on - but
even 1mm means that your printer is extruding incorrectly by 1%.
After marking where 100mm actually was, you will want to compare it to
where you measured 100mm to be at the beginning of this process. If higher
on the filament, your printer is over extruding, if lower on the filament,
your printer is under extruding.
After measuring this difference you will want to write down somewhere
how much your extruder actually fed. If your printer over extruded by
2.1mm, you will want to mark down 102.1mm. If it under extruded by
2.1mm, you will want to mark down 97.9mm. You will need this number
later on.
The next step in this process is to determine what your current E-Steps are.
You can do this by either checking the firmware for your machine, by going
into the “Motion” section of your EEPROM (LCD Screen), or just by
giving it the command “M503” in your printer terminal. Non-geared
extruders have E-steps of around 90, while Greg’s wade and other geared
extruders can have E-Steps of 500 or more. Something like the Titan has a
starting point of 420. If you have an extruder from a popular manufacturer,
they will list what their standard starting point for E-Steps should be.
If you are checking in the firmware that you use to flash your machine, you
will want to open it up. While in Marlin you will go to the
“Configuration.h” tab and scroll all the way down to where it says
“DEFAULT_AXIS_STEPS_PER_UNIT”, with E-steps being the 4th and
final number (if using one extruder). The X, Y, and Z steps should never be
changed and are a calculation based off of the parts you are using.
You could also type M503 into your terminal to be given a readout of what
your current E-Steps are. You can then set the E-steps to the starting point
of your new extruder. If you are using a Titan extruder, you would type
“M92 E420”. Then you would type M500 to save the settings. You can then
run the 100mm feed out as explained above to tweak this number further.
After running your 100mm feed out test, you then take your current E-steps
number and multiply it by 100 (the amount you were attempting to
extrude). You will then divide this new number by the number you wrote
 ) y y
down earlier.
If you decided to check your E-Steps by feeding out more than 100, you
would multiply by that number. I actually will often feed out 200mm
instead, in order to get back a more accurate number. Just remember to
change the calculations accordingly.
For example, if your current E-steps are 90.5 as shown in Marlin above, you
will multiply it by 100 to get 9050. We will then divide 9050 by how much
you extruded earlier. So if you extruded 102.1mm, you will take 9050 and
divide it by 102.1 to get 88.64.
90.5 x 100 = 9050
9050 ÷ 102.1 = 88.64
88.64 in this above example would be your new E-steps. As you can tell it
is lower than it was before, because in this example you were correcting for
over extrusion.
You will now set your E-steps. You can do this through your terminal,
EEPROM, or by flashing your firmware. If you are going to do this through
your terminal you will want to give the M92 command, by typing “M92
E88.64”. You will then want to type “M500” in order to save these settings.
Without typing “M500”, the number will be reset when turning off your
machine.
While you can set this number on LCD screens under the “Motion” section,
it will only save permanently if you have the option to save your settings
after doing so, just as with typing M500 in the example above. Otherwise
your E-steps will reset once you turn your machine off.
Thomas Sanladerer has a great older tutorial video going over all of this on
his channel which you can find by searching “calibrating your extruder” on
YouTube. Thomas really knows his stuff and I suggest to everyone that they
follow what he does.
Clean your build plate
Cleaning your build plate frequently will help to prevent bed adhesion
issues. Don’t wait until your print won’t stick before you clean your bed –
proper precaution is important.
Depending on your build plate and what you were using for adhesion will
determine how you clean, but I suggest to everyone that they clean their
plate after every 5 prints or so. This is especially important when working
with PEI beds, since they will gradually lose their adhesion as they become
dirty.
Lubricate Rods and Leadscrews
Grab a paper towel and clean off all of your metal rods. Then get some
white lithium grease and rub it over both your smooth rods and threaded
rods. While the bearings you use are advertised as “self-lubricating”, they
don’t last forever.
After adding some grease, move all of your axis to all positions. This will
help spread the grease out and you should notice a distinct difference in
moving your carriages around.
Tighten all screws and bolt on your
machine
Frequent rattling of your machine can get screws and bolts loosened on
your machine. If you haven’t checked in a while, you will be surprised just
how many aren’t tight anymore.
When I say check every screw, I mean every single one. The ones holding
your frame together, the ones holding your build plate, the ones holding
your extruder – all of them. The last time I did this I had waited about 2
months. I found over 5 screws that had become entirely loose. Consider
adding non-permanent thread locker to your screw threads to reduce the
impact of vibrations over time.
These loose screws can lead to z-wobble or entirely failed prints. Take the
precautionary steps to prevent this from ever happening.
Note about ghost printing:
If you have a printer that looks like it is printing, but isn’t, it could be a few
issues as noted in the “Diagnosing Failures” section. If you checked the
other tips mentioned, and none worked, it could have to do with this need
tighten all screws.
If you are able to push down filament without any issue, but the extruder
just wont extrude filament (or just stops randomly), the hobbed gear on
your extruder may not be tightened snug to the stepper motor. The hobbed
gear which turns and feeds filament based off of your stepper motor turns is
connected to your stepper motor via a tiny threaded insert. If this threaded
insert becomes loose, the hobbed gear may spin freely around the stepper
motor. This means that as your extruder turns, no filament is fed out.
This can result in a print that is “ghost printing”, where your printer looks
like it is moving just fine, but no filament is being extruded, and there is no
clog to speak of.
Material and their Settings
By this point you are well aware that different manufacturers with different
printer setups will require different specific slicer settings. That said, I will
review some of the settings that work best for me on both a geared direct
drive and geared Bowden machine. These will be good starting points,
though the speeds should be turned down a bit when working with non-
geared extruders.
While Bowden machines can move faster without experiencing rattling,
since the carriage is much lighter without the extruder, they are limited on
specific materials due to the distance between the extruder and hotend. This
also means it is more likely to print stringy and have difficulty travelling
over small distances without leaving a trail, requiring an increased speed
and distance for retraction.
All of the settings below are editable in Cura 4.0 and higher, and likely
editable in your slicer as well. Make sure to read the PLA section entirely
regardless of what material you are printing with, since there are some
overall notes factored within.
Also note that speed that I mention, including retraction, can depend on
what extruder you are using. I personally use a Bondtech BMG dual drive
extruder, which can handle higher speeds than a non-geared extruder. These
are just starting points to which you can tweak later if the quality is not to
your liking.
** This chapter will go over the basics for printing with materials, but does
not go into the actual science of what makes up different types of filament.
For that, you should continue to the next section for the newly added
“Material Science” chapter, contributed by Nicolas Tokotuu of Polymaker. I
suggest everyone reads that next chapter since it will explain the “why” on
everything, and how you would definitely want to tweak the settings you
read below depending on your exact setup.
If you would like further information about 3D Printing materials, I would
suggest you visit OptiMatter by SD3D (OptiMatter.com). OptiMatter
provides a wide range of data on materials used for 3D printing and can
even help to calculate the best printing configuration for you.
NOTES ABOUT ALL MATERIALS:
This will be covered in the “Settings” section in this book, but first I will
cover a few specific slicer settings that will be used regardless of the
material. I almost always use Triangles or Hexagonal infill patterns, since I
see no need for many of the other options, and I will always have at least
1mm of top layers. I keep acceleration and jerk lower than most other
operators because I notice this is one of the most important things to keep
low for a clean print, but it does increase the print time required. Both
acceleration and jerk can be set higher on a Bowden machine though, due to
its decreased carriage weight.
Make sure you always properly purge the filament when switching between
materials in order to reduce the chance of black blobs on your print. Read
the “Built up Material in Nozzle” chapter for a further explanation.
As of writing this book, Cura also has an experimental feature called
“Coasting” that I use for almost every Bowden print. You will see
throughout this section that Bowden machines come with an increased
difficulty reducing stringy and hairy prints. Coasting replaces the last part
of an extrusion path with a travel path, meaning the oozed material is used
to print the last piece of the extrusion path to reduce stringing. This is great,
but if you go too high, you can experience under extruded prints. For most
materials I use the following Costing settings on Bowden machines:
Coasting Volume: 0.064 (nozzle diameter cubed)
Minimum Volume Before Coasting: 1mm3
Coasting Speed: 90%
Please also note that I am currently tweaking my travel speed settings due
to further understanding from Polymaker and Nicolas’s “Material Science”
chapter contribution. Since travel speed really shouldn’t affect the quality of
your print, you should be able to bump this up to the highest you are able to.
This not only will save on print time, but should reduce the amount of
oozing debris/hair left on your prints. So while I have a travel speed of
100mm/s on all materials down below, I am now playing around with
speeds around 200mm/s.
PLA
Polylactic acid (PLA) is the most common and easiest to use 3D printing
material. While PLA has a very high tensile strength, it has a very low
bend-to-break ratio, making it one of the most brittle materials upon impact.
The low glass transition temperature means that the printed part cannot
withstand heat higher than 50°C without deforming, which means parts will
deform when left on the dash of a hot car. These two factors mean that PLA
is likely not going to be your choice for practical mechanical parts.
While you aren’t going to be using PLA as a load bearing mechanical
material, it has numerous other applications. Its ease to print, low shrinkage
rate and inexpensive price makes it the perfect choice for models,
prototypes for sizing, molding, cosplay, and other fun prints. Being a stiff
part that holds its dimensions makes it a great choice for anyone wanting to
make a negative cast for molding. For these exact reasons I personally use
PLA far more than any other material. All of my fan art around my house
and most of the examples used in my YouTube videos are made via PLA.
PLA Slicer Settings:
Print Temperature (180° - 220°C)
This print temperature range is huge and is only this large due to the vast
variations among individual manufacturers. Most PLA manufacturers either
ship their filament with a processing temperature range of 180°- 205° or
205°-220°, you just have to check with your individual spool. Even then,
these ranges are larger than the average material you work with, and you
will find that you may be able to achieve a successful print almost
anywhere within these ranges. My personal choice is to go to the higher
side of the material range. I like to print around 200°C in the materials with
the lower range, and around 212°C with PLA that has the higher range on
both Bowden and Direct Drive machines - though you can play around a bit
and lower if you are experiencing blobs.
Build Plate Temperature (50 - 60°C)
PLA is a bit unique in the fact it can actually print on a bed that is not
heated, but it will stick and work best on one that is heated to its glass
transition temperature of around 60°C. You can go down to 50°C if you are
experiencing “elephant foot”, as explained in that chapter.
While working with a 60°C build plate, you can actually just print directly
onto a clean glass bed, but it is best to add additional adhesive. My favorite
adhesive solution is some hair spray since it is easy to add, remove, and
keeps the underside of the print clean. When working with a printer that
does not have the ability to heat it’s bed, you will need to go out of your
way to make sure the part can stick on the initial layers beyond just hair
spray. This is when you will likely want to use blue painters tape or another
form mentioned in the “Bed Adhesion” chapter, along with including a brim
or raft on just about every print. Having a heated bed will definitely reduce
your headaches, but it is not mandatory for this material.
While working with a heated bed, I reduce the amount of times I use a brim
to as minimal as possible. This is because most models should stick just fine
without warping and removing a brim for PLA is not nearly as easy as it is
on other materials. I have definitely regretted using a brim in the past when
printing 30 small parts on a single bed – leading to an extra couple of hours
of post-print manual cleanup.
Retraction: (Direct Drive: Distance: 3.5mm – Speed: 35mm/s – Minimum
Travel 0.9mm) (Bowden: Distance: 4.8mm – Speed: 55mm/s – Minimum
Travel – 0.8mm)
Please note that retraction may need to be tweaked for individual models.
Some models require retraction to be turned off entirely in order to print
properly, but these are good starting points for your average model.
This is the setting that has the most difference between a direct drive and
Bowden setup. Due to the pressure built up between the extruder and
hotend in the Teflon tubing, Bowden has increased propensity for
stringiness and so will require increased retraction settings on every
material (some more than others). With a geared direct drive setup, these
retraction settings work great on most PLA manufacturers that I have used,
with minimal tweaking required for specific models.
Bowden machines need more tweaking than direct drives when it comes to
this regard. Some models may be under extruded with these settings and
need you to reduce the distance and speed. This is why I often tweak with
the minimum travel. If you have a part that requires a lot of retraction to
reduce stringiness, but there are a couple very small areas on your print that
will be under extruded, you can bump this number up so that no retraction
occurs over those small sections.
I almost always also keep the COASTING option turned on for Bowden
prints, available in Cura 3.3 and newer, mentioned in the ‘Notes about All
Materials’ section a few paragraphs earlier.
Speed: (Direct Drive: Speed: 55mm/s - Outer Wall: 27mm/s – Top/Bottom:
30mm/s – Initial Layer: 20mm/s – Travel Speed: 100mm/s) (Bowden:
Speed: 60mm/s – Outer Wall: 30mm/s – Top/Bottom: 30mm/s – Initial
Layer Speed: 25mm/s – Travel Speed: 100mm/s)
Please note that I normally suggest starting around 45mm/s on non-geared
extruders, but since I am running a dual drive geared extruder, I bump this
up to the 55mm/s you see above.
This section will get a lot of dispute from other experienced users, and
definitely is different than the manufacturer advertised speeds. Personally, I
don’t mind a print taking an extra hour or two if it means that the quality is
increased and the chance of failing is decreased. Reducing these numbers
(as well as jerk and acceleration) from the recommended settings has done
nothing but improve my print quality and reduce my failure rate.
PLA is the material I run the fastest due to its ease of printing. A light
Bowden allows for fast printing, and if your setup has very little rattling
with a geared extruder, you can likely go 65mm/s without any reduction in
quality. Due to its rigidity, PLA is an excellent material for fast processing
on a Bowden setup because it will not compress much, if at all, in the
Teflon tubing.
Anyone saying they can achieve print speeds over 150mm/s is either lying,
getting poor quality prints, has a very experimental machine, or does not
understand how acceleration works. For any print to reach its top speed,
enough distance is required and acceleration speeds set high enough to
reach these speeds.
If your printer starts rattling when moving in-between parts, reduce your
travel speed. If you don’t see any ghosting and your parts are coming out
extremely clean, you can try bumping speed and acceleration up to see if
you get the same results.
These settings are also for when I am printing 0.2mm layer heights on a
0.4mm diameter nozzle. When printing with a very small nozzle at very
small layer heights, these speeds will drastically need to be reduced. When I
print on a 0.25mm nozzle I reduce everything by about 20%, and I drop my
print speed all the way down to 25mm/s when running the extremely small
0.15mm nozzle.
While you should be able to achieve faster speeds than this when using a
large nozzle diameter at large layer heights, you run into the issue of
overheating your extruder stepper and getting skipped steps. You can keep
speeds as they are if you have a powerful extruder, but it is also likely you
will need to reduce these speeds when going over 0.6mm diameter nozzles.
When I print with a 0.8mm diameter nozzle at 0.5mm layer heights I also
have to decrease my speeds by about 20%.
This is one of the benefits to getting a Volcano or SuperVolcano hotend by
E3D. They allow for faster printing with these large nozzles since they
allow for a larger melt zone without causing heat creep in the barrel. If you
want to print fast, large diameter nozzle and layer height prints, you will
want to invest in one of these Volcano hotends.
I have a video titled “Taking it to the Extreme with the SUPER Volcano” in
which I show how these speeds can be much higher when using this new
hotend.
Support Settings: Overhang Angle: 50-55° - Density: 12% - Z Distance:
0.2mm – X/Y Distance: 0.8mm – Enable Support Interface – Interface
Thickness: 1mm – Interface Density: 90% - Interface Pattern:
Concentric)
These settings are the ones that will require the most additional tweaking
for your individual printer and model. These are also for single nozzle
parent support material. If you are using dissolvable support material, you
will likely want to increase the density and decrease the Z distance. The
12% density may be too little for specific models, as well as the overhang
angle, but since the interface density is so high, the underside of your print
should hopefully still be clean. If you have support interface turned off,
make sure you increase the density. Your Z distance is entirely dependent
on your layer height, since it will always be a multiple of your layer height.
I have found that the support interface works great with PLA with difficult
overhangs, it will just require you to be extra careful when removing the
support material. Since PLA is so rigid and brittle, the part can easily break
when trying to remove stubborn support that was not processed with the
right settings. With the settings I provided above, it results in a very clean
underside with support material that can kind of be “cracked” off in a
couple of sections, with a minimal amount of razor cleanup.
There is a video on my YouTube channel titled “Detailed Cura Support
Settings” in which I go over this further in depth. I can’t stress enough how
much support interface has helped with the quality of my prints ever since it
was first introduced in Cura a little over a year ago, and I suggest everyone
to check out that video so you understand exactly what is happening, along
with examples of my prints.
NOTES ABOUT PLA:
PLA is the easiest of the materials you will read about in this section to
work with. You can get just as clean results with all of these settings
tweaked slightly. As with almost all materials, PLA also can absorb
moisture when not stored properly, though not quite as common. If you
want to check if your PLA is good to work with, it should be breakable with
a bend on the spool, or with a slight amount of effort. If it requires you to
get scissors out to cut the material, since you cannot break it, it likely has
absorbed moisture and needs to be dehumidified. If it is extremely brittle to
the touch where it breaks without any effort at all, there is also an issue with
the spool that will result in poor quality prints.
Since PLA is one of the least warping material, you should also always
have your active cooling fan on full blast after the initial layer. This makes a
drastic difference in surface quality and overhangs achievable.
ABS
Acrylonitrile butadiene styrene (ABS) was the second most used material
by myself, as it was always the go-to material for mechanical parts with a
low price tag. ABS is what LEGOs are made out of, and its properties make
it a great choice for mechanical parts as well as those requiring a high heat
resistance, handling a heat deflection temperature up to 95°C (or 205°F). It
is also soluble in acetone, allowing you to blend layers together and add an
injection molded shine in an acetone vapor bath.
One thing you will hear from just about every experienced 3D printer is the
difficulty to print this material without warping and delamination. Small
parts may be achievable, but any large model will require a well-built
enclosure with ambient air of over 50°C for any hope of success. Even with
this environment, a level PEI build plate, and a model with 30 lines of brim,
it is difficult to get a non-warped part weighing over 500 grams. This is why
you will need an ABS Slurry for very large prints, and this added difficulty
has turned ABS into a material I only use for small models. This is
explained further in the next chapter.
You will want to keep your active cooling fan OFF when printing with ABS
to help prevent warping.
ABS Slicer Settings:
Print Temperature (220° - 240°C)
ABS has a slightly higher printing temperature than PLA. I seem to prefer
to print ABS at 230°C, but you may have better results tweaking within this
range. Always check with your manufacturer’s suggestions first.
Build Plate Temperature (105°C)
This is one of the reasons it is so difficult to print ABS – bed adhesion.
With a high glass transition temperature, you will want to run your print bed
at a hot 105°C.
The issue with this will come from having drastically different ambient air
temperature. Having cool air surrounding your print will cause those areas
to want to shrink before the bottom of your print, leading to warping and
delamination.
I have no problems printing small parts in ABS on an open printer, but it
would be smart to print anything of size on an enclosed machine. I have
been able to reach ambient temperature of over 55°C in an enclosed
machine, which works perfectly to prevent warping and delamination. You
just need to make sure the electronics used inside the machine can handle
those temperatures, and that your board is located outside of this enclosure.
Even when having your print bed at 105°C, warping will still occur. I
personally just use Aqua Net hairspray on a glass bed for adhesion, but this
won’t work on large parts. If your part absolutely needs to stick and has to
be in ABS, you will need to make an ABS slurry if your printer is not
entirely enclosed (explained further in the “Bed Adhesion” chapter).
I haven’t used an ABS slurry in roughly 3 years because I have essentially
switched to Nylon blends and PETG for parts that require a lot of strength.
Retraction: (Direct Drive: Distance: 1.8mm – Speed: 15mm/s – Minimum
Travel 1.2mm) (Bowden: Distance: 3.5mm – Speed: 35mm/s – Minimum
Travel – 1.2mm)
For ABS I reduce my retraction settings a bit from PLA. It seems that ABS
doesn’t have as many issues with “stringiness” or “hairy” prints as other
materials, so these numbers don’t need to be quite as high. This is because
ABS has a lower heat capacity than most of the materials we work with.
PLA, PET and elastomers have much higher heat capacities. The lower the
heat capacity, the faster the material can cool. This leads to less stringing
but also lower interlayer adhesion. ABS is also still fairly rigid so it doesn’t
have to deal with extreme compression like what would be dealt with when
processing a nylon or elastomer on a Bowden setup.
If you are experiencing stringing with these settings, increase accordingly,
or use “Coasting” if applicable on a Bowden setup.
As with PLA, each model may require different retraction settings, with
even some models having you turn retraction entirely off.
Speed: (Direct Drive: Speed: 45mm/s - Outer Wall: 25mm/s – Top/Bottom:
40mm/s – Initial Layer: 25mm/s – Travel Speed: 100mm/s) (Bowden:
Speed: 55mm/s – Outer Wall: 30mm/s – Top/Bottom: 30mm/s – Initial
Layer Speed: 25mm/s – Travel Speed: 100mm/s)
As with all materials, speed is also going to be limited by the machine you
are using. Travel speed can be bumped up if you are using a strong, reliable
machine, but you will always be limited based on acceleration and
deceleration speeds. This is why a large printer can normally reach higher
top speeds than a small one, having a longer period of time to accelerate
and decelerate.
My CR-10 Bowden machine is limited to a travel speed of around
150mm/s, since the motors start making some loud noises over this. This
being said, I print ABS at around the same speeds as PLA. Some machines
advertise speeds much higher than this, but I always suggest starting low
and increasing until failure.
These are settings for a 0.4mm nozzle and 0.2mm layer heights. These
speeds will have to be decreased with smaller nozzles and layer heights, and
can be increased with higher ones.
Support Settings: Overhang Angle: 45-50° - Density: 15% - Z Distance:
0.2mm – X/YDistance: 0.8mm – Enable Support Interface – Interface
Thickness: 1mm – Interface Density: 90% - Interface Pattern:
Concentric)
ABS is another material that I prefer to use the support interface on in order
to improve underside quality. From my tests it seems that ABS cannot
handle angles that great, so I will often set the overhang angle to 45°.
Since I keep the cooling fan OFF on ABS, it also seems to have more
difficulty bridging gaps. Because of this, I bump the density up slightly to
15% just to make sure the support interface lays down cleanly. I personally
see no reason to go higher than 90% support interface density on any
material, so I keep that the same regardless.
NOTES ABOUT ABS:
ABS is slowly being used less and less in 3D printing as easier, strong
alternatives present themselves and their prices continue to drop. The rate of
me getting a failed print while using ABS is much higher than just about
every other material (with a few exceptions such as PCABS and other very
high temp filaments).
One of the best parts about printing in ABS is the fact is soluble in acetone,
meaning you can smooth the outer sections and make it more watertight, for
a more injection molded look and feeling. You can do this via a crock pot
on low for 10-20 seconds with your print lifted, you just have to be very
careful doing this. For a further explanation, please read the “Post-
Processing” chapter in this book.
PETG
Polyethylene terephthalate with a glycol modification (PETG) is a plastic
resin of the polyester family that is used in beverage containers, food
packaging, and countless other everyday applications. While it is used for
food containers, it is not recommended to use any 3D print for food parts,
due to the minor gaps created in-between layer lines where bacteria can
grow.
PETG has slowly become the main replacement for ABS, becoming the go
to filament for strong mechanical parts at a low price tag. You can get a
1KG spool of PETG for only a couple of dollars more than PLA, and you
can easily print a large piece without warping - so you will likely want to
use this for the majority of your ABS applications.
Assuming you don’t have a large budget, and do not need your part to
withstand higher than 70°C, then PETG will likely be your choice over
ABS.
PETG is very susceptible to stringiness due to its high heat capacity, and
you can end up under extruding by attempting to rectify it via increasing
retraction, so you may need to clean this stringing up post print on specific
models.
PETG Slicer Settings:
Print Temperature (240° - 260°C)
Some say that you can print PETG below 240°C, but I personally have
always printed at 250°C successfully (with minor tweaks for small/large
nozzles and layer heights). Always check your filament manufacturers
recommended settings, since some manufacturers will have a different
range than I listed above.
Build Plate Temperature (70° - 85°C)
You can actually print PETG without a heated bed, but it isn’t simple. When
heating to 70°C, and having a fully level bed, PETG sticks great and has no
problems with warping. This, like the print temperature, can have a
different range depending on the manufacturer.
I have printed parts that take up the entire 300mm x 300mm x 400mm build
area of the CR-10 in PETG with absolutely zero problems with warping or
delamination, though you will have to be confident on the manufacturer. I
personally like Fiberlogy (sold by Wolfworks 3D in the USA) for my PETG
needs, since it is the cleanest and strongest I have tested thus far.
Retraction: (Direct Drive: Distance: 3.5mm – Speed: 35mm/s – Minimum
Travel 0.7mm) (Bowden: Distance: 5mm – Speed: 55mm/s – Minimum
Travel – 0.7mm)
Many of the settings for PETG are similar to PLA, but I have found a
slightly increased retraction to help out immensely to reduce stringiness. As
mentioned earlier, PETG seems to ooze out more than other materials, so
you will want a bit of an increased retraction over PLA, and you will also
want to have Coasting turned on for Bowden prints.
If you see under extrusion after increasing these numbers, reduce these
settings and you will just have to clean off the string post-print with a blow
dryer or a razor.
Speed: (Direct Drive: Speed: 50mm/s - Outer Wall: 25mm/s – Top/Bottom:
40mm/s – Initial Layer: 25mm/s – Travel Speed: 100mm/s) (Bowden:
Speed: 55mm/s – Outer Wall: 30mm/s – Top/Bottom: 30mm/s – Initial
Layer Speed: 25mm/s – Travel Speed: 100mm/s)
This sounds a bit crazy, but I keep everything just about the same as I do
when printing with PLA. These numbers worked perfectly so I saw no
reason to change anything.
Keep in mind, as with all materials, these settings are for a 0.4mm nozzle
and 0.2mm layer heights, with speeds needing to be tweaked if you are
using something different.
Support Settings: Overhang Angle: 60° - Density: 12% - Z Distance:
0.2mm – X/Y Distance: 0.8mm – Enable Support Interface – Interface
Thickness: 1mm – Interface Density: 80% - Interface Pattern:
Concentric)
While I keep the actual support settings the same as PLA, the angle which
support is required is much higher than PLA. When printing overhang tests,
it seems that PETG achieves some of the cleanest overhangs of any
material. This means you can go all the way up to 60° without requiring any
support material, saving you a ton on material and time required to print lots
of models. I have actually achieved 65° without the need of support
material, which is quite high for any material.
With the support interface you may need to get your razor out, but
removing support should essentially “crack” off and leave you with a very
clean underside.
Every PETG I have ever tested has had a lot of difficulty bridging. So while
you can achieve some great angles, you will not be able to bridge large
sections without support material.
NOTES ABOUT PETG:

There is a video on my YouTube channel titled “PETG Cura Settings” in

which I go over this more in-depth, though that was using a PETG material
I do not really prefer any longer. I go over my testing of my current favorite
PETG in a video titled “Fiberlogy PET-G Review”.
I have always used the active cooling fan “on”, but others have said to keep
it off for increased layer adhesion. If you are noticing difficulty with layer
adhesion, try turning the active fan off. If you are getting some ugly surface
quality with the fan off, try turning it on and see if the strength of your part
does not decrease.
PETG also seems to have difficulty bridging gaps (when compared to
PLA), so you will require support settings turned on for small gaps
Flexible Filaments

Flexible
filaments come in a wide variety of properties and print settings, so it is just
about impossible to give an all-inclusive profile. I have made 2 YouTube
videos in which I go over 10 popular flexible titled “3D Printing Flexible
Filament Comparison” part 1 and 2 to get a bit more of detailed description
of options available.
While there are quite a lot of flexible options out there, my personal favorite
for a lot of applications is Cheetah by NinjaTek.

NinjaTek makes
NinjaFlex, one of the most flexible options available on the market, but it is
extremely difficult to print. Cheetah was created in order to fix this by
allowing you to print faster, hence its name. I will be using Cheetah below
as the example because of this, and because of the fact you can print this on
a Bowden machine such as the CR-10 with an upgraded extruder.
Some overall notes for flexible filaments:
• All flexible filaments print better on a direct extruder vs. a Bowden
machine, and some flexible materials are entirely impossible to print on a
Bowden extruder.
• The general rule of thumb is – the softer and more flexible the material –
the harder it is to print, and the more you need a direct geared extruder.
• You will need a geared extruder rated to print flexible filaments in order to
print a wide variety of flexibles. You can print a basic Greg’s Wade and
purchase minimal parts, or you can purchase an upgraded extruder. My
favorites are the E3D Titan, and the Bondtech BMG Extruder. The
Bondtech BMG has a dual-drive, meaning there are two gears gripping onto
the filament. This, along with a 3-1 ratio, makes it my favorite extruder to
use when having difficulty printing flexible filaments. I have yet to find a
material I can’t print when using this Bondtech BMG as a direct extruder.
• Slow your print down! Print at speeds about 25% lower than
recommended manufacturer settings to start with, and reduce further if
needed. For some very soft materials such as 3DXFlex and NinjaFlex I
have to print at 25mm/s in order to not experience a failed print.
• The harder the flexible filament, the easier it is to print. Almost any
flexible filament with a shore hardness of 90A or lower is very difficult to
print
• You may not be able to use smaller than a 0.4mm diameter nozzle,
depending on how flexible the material is.
• Parent support material is extremely hard to remove. Flexible filaments
with a large bend-to-break ratio have high layer adhesion, making parent
support material very hard to remove cleanly. Because of this, I do not use
support interface. You should always factor in the difficulty to remove
support material when designing your flexible part.
CHEETAH Slicer Settings:
Print Temperature (235° - 245°C)
Flexible filaments have a wide range of printing temperature depending on
the particular manufacturer. For Cheetah, I have found good results printing
at 240° while something like Tough 3D Ink by M3D prints better at 250°C.
Build Plate Temperature (45°C)
Many flexible filaments seem to prefer a print bed temperature of just 45°C,
but there are of course exceptions to this. NGEN by ColorFabb requires a
print bed of 80°C and PCTPE by taulman3D requires a coat of PVA be
applied to prevent warping. Cheetah seems to print just fine without any
warping with a 45°C glass bed and Aqua Net Hairspray.
Retraction: (Direct Drive: Distance: 2mm – Speed: 20mm/s – Minimum
Travel 1mm) (Bowden: Distance: 3mm – Speed: 40mm/s – Minimum
Travel – 1mm)
I have retraction turned down from other materials due to the difficulty to
print flexible filaments. Since speeds in general are reduced, retraction
speeds should be reduced as well.
If you are printing a part that requires a lot of retraction and are doing it in
flexible filament, even Cheetah, you are going to be left with some string
you will have to clean up post print. You just need to grab a razor and
scrape off the residue left on the print. There isn’t much that can be done to
help this.
Speed: (Direct Drive: Speed: 40mm/s - Outer Wall: 20mm/s – Top/Bottom:
35mm/s – Initial Layer: 20mm/s – Travel Speed: 100mm/s) (Bowden:
Speed: 35mm/s – Outer Wall: 17.5mm/s – Top/Bottom: 17.5mm/s – Initial
Layer Speed: 20mm/s – Travel Speed: 100mm/s)
I am able to print cheetah faster than any other flexible filament, so these
will be the upper bound for flexible materials. Remember you require an
upgraded extruder (and likely hotend) if you want to print Cheetah on a
Bowden machine such as the CR-10. I currently have a Bondtech BMG on
my CR-10 and it is able to print Cheetah like a champ with the settings
provided.
That being said, even with this $100 upgraded extruder and a $60 upgraded
hotend, I am unable to print extremely soft materials such as 3DXFlex on
my Bowden CR-10 regardless of how slow I run the print. If you plan on
printing a lot of flexible filaments, it is worth your money and/or time to
upgrade to a geared direct drive setup.
My CR-10 with a direct Bondtech BMG extruder has printed every flexible
filament that I have tested thus far without any issues – which should show
you the benefit over Bowden.
Support Settings: Overhang Angle: 50° - Density: 15% - Z Distance:
0.2mm – X/Y Distance: 0.8mm – Disable Support Interface)
These settings are definitely not perfected, but they work well for me while
printing with Cheetah. As mentioned in the earlier notes, removing parent
support material both cleanly and easily is near impossible with certain
flexible filaments.
The overhang angle when support material is required will need to be found
out for each material. NGEN by ColorFabb can get closer to 60°, so make
sure you print an overhang test to find out when you will need support.
NOTES ABOUT CHEETAH:
Cheetah has been the easiest to print flexible filament for me, so make sure
you decrease most of these numbers when working with other materials.
Some flexibles require a specific print bed since they have a nylon mixture.
Always store your flexible filaments in dry area vacuum sealed with some
desiccants. This is true with all materials, but flexibles and nylons absorb
water the fastest and will need to be vacuum purged if left out in a semi-
humid area.
Nylon Filaments
Nylon can also be referred to as a polyamide and are generally strong (and
often semi-flexible) options for 3D printing. Almost all nylon options
offered on the market are more expensive than PETG, but they are best for
many applications. If you require impact resistance, you are likely going to
want to with nylon due to its durability to flexibility ratio.
The strongest material I have ever tested to date is actually a Nylon. It is
PolyMide CoPA by Polymaker, and I am not just saying that because they
have contributed a chapter to this book. You can view my video “Nylon
Comparison Part 1” on YouTube to see exactly how I have come to this
conclusion. If you need strength – check this material out.
Nylons come in a wide variety of options, but almost all have a bit of
difficulty sticking to build plates without extra help. As mentioned
elsewhere in this book, you will likely want to grab some Elmer’s glue, do a
1-1 mixture with water, and lightly brush it onto a clean glass build plate.
After evaporated, nylons will stick great and pop off fairly easily with a
scraper. You can also use a glue stick if that is your preferred method.
This may not be needed for all nylons, but I prefer doing this for most to
prevent warping or parts being knocked off the print bed.
For the example below I will be using PolyMide CoPA by Polymaker since
it is my current favorite nylon material, but every single nylon will require
its own settings.
Some overall notes for nylon filaments:
• Nylon is hygroscopic and must be kept dry. This is not an option as
leaving out your nylon spool can actually make it absorb too much moisture
in a matter of a day or two. You should keep all nylon spools vacuum
sealed, and in a dry area (45% humidity or lower).
• Many nylons have a shelf life and will not print as well after a year of
being on the shelf, regardless of how well you store it.
• Nylons are very durable and have an excellent strength to flexibility ratio.
• Nylons often do not come in many color options, but most can be dyed
(since it can absorb moisture). I have tried this in the past to mixed results.
• Just as with flexible filaments, removing parent support material can be
very difficult with Nylons.
PolyMide CoPA Slicer Settings:
Print Temperature (263°C)
PolyMide is one of the few nylon mixtures that does not require PVA on a
glass build plate, but I still do it as to help mitigate any bed adhesion issues.
While PolyMide requires a higher print bed, the majority of nylon materials
I have worked with in the past prefer a 45°C print bed, and the vast majority
require a glass bed with a PVA mixture to print. Refer to the beginning of
this Nylon section to read further on how to do this properly, and refer to
the next chapter to understand why.
Most nylons shouldn’t give you much issue warping, but some, such as
Alloy 910 by taulman3D, has warped on me in the past. You just need to
make sure you evenly apply your PVA mixture and that your bed is levelled
at the correct z-height.
Check with the manufacturers recommended print bed settings to be sure.
Retraction: (Direct Drive: Distance: 3.5mm – Speed: 35mm/s – Minimum
Travel 1mm) (Bowden: Distance: 4mm – Speed: 40mm/s – Minimum
Travel – 1mm)
Without going too much into detail, these settings seem to work well with
me and this filament. There isn’t much to go over here, but you will need to
tweak accordingly depending on the nylon you end up using.
Speed: (Direct Drive: Speed: 45mm/s - Outer Wall: 22mm/s – Top/Bottom:
22mm/s – Initial Layer: 20mm/s – Travel Speed: 100mm/s) (Bowden:
Speed: 40mm/s – Outer Wall: 20mm/s – Top/Bottom: 20mm/s – Initial
Layer Speed: 20mm/s – Travel Speed: 100mm/s)
These settings worked for me when working with PolyMide CoPA, but may
not be great for other Nylons. Since the CoPA is a decent amount stiffer
than many other nylon blends, you will likely need to go slower than this
for other manufacturers.
I don’t recall working with a specific nylon that required drastically slow
print speeds, so proceed with what I have above, unless you read otherwise
by the manufacturer.
Support Settings: Overhang Angle: 50° - Density: 15% - Z Distance:
0.2mm – X/Y Distance: 0.8mm – Disable Support Interface)
These settings stay the same as flexible filaments due to the difficulty to
remove the support material cleanly. If you cannot remove the support
material and it is stuck to the print, increase your Z distance.
If you notice a lot of drooping and that the particular nylon you are working
with is unable to bridge gaps, increase the density. If you think you will be
able to remove the filament, go ahead and test out support interface – I just
personally haven’t had great results in being able to easily clean it all up.
NOTES ABOUT POLYMIDE COPA NYLON ALLOY 910:
I haven’t done a ton of work with PolyMide CoPA, but what I have done
has impressed me immensely. It is the only material I have ever done my
strength test on that I was unable to break whatsoever. Polymaker has made
me a believer when it comes to this material – especially since it is not that
difficult to print.
Alloy 910 is another favorite of mine made by taulman3D and was a go to
for me whenever I really need a part to have strength (until discovering
PolyMide CoPA). I have used this material twice now for 3D printed
planetary gear skateboard wheels, and they held up to a LOT of impact.
They wouldn’t break no matter how hard I jumped on my skateboard, and
they eventually cracked under the pressure of a few professional
skateboards (which can be seen in a couple Braille Skateboarding YouTube
video). Compared to an ABS set that broke the moment I jumped on my
board, it is clear nylons have their place in 3D printing.
Finding the right elasticity, shore hardness, and tensile strength for your part
may be difficult, but there seems to be a wide variety of nylon options on
the market today. You just need to think about what you need for your
particular application.
Carbon Fiber Reinforced and Filled
Filaments
Carbon fiber reinforced materials are filled with continuous fibers or fiber
particles that result in parts with improved physical properties and high
stiffness. There is a variety of carbon fiber reinforced options out there for
3D printing, but they all require drastically different print settings. Because
of this, I will not be going over particular slicer settings. In general, you
will need similar settings to the material that Carbon Fiber is reinforcing.
This means when working with Carbon Fiber Reinforced PLA, you will
want to use similar settings to that of PLA. The same is true with ABS and
Carbon Fiber Reinforced ABS, and so on.
Essentially, you will want to use carbon fiber reinforced materials when you
require properties of the original material, but with a higher tensile strength.
Carbon Fiber Reinforced ABS has the high glass transition temperature of
ABS, yet is much more stiff and strong. It is also easier to print. Carbon
Fiber Reinforced Nylon is an awesome combination, one that is perfect for
a wide variety of strength and heat resistant applications.
Personally, I have never found a use for Carbon Fiber Reinforced PLA,
since it turns out more brittle than standard PLA (due to a lower
elongation), but I am sure there applications for everything.
You will HAVE to work with hardened steel or ruby tipped nozzles when
working with carbon fiber nylons, since the hardness will add abrasion and
lead to your brass nozzle being worn out rapidly fast. A hardened steel or
ruby tip nozzle will have a higher hardness than the carbon fiber blend and
should not wear down your nozzle (or it will at least take much, much
longer).
I am not going to include specific slicer settings for carbon fiber blends
because they all vary drastically depending on what the carbon fiber is
blended with. Just please note that as of now, all carbon fiber blends have
lower layer adhesion properties.
Material Science
Written by Nicolas Tokotuu, Product
Manager at Polymaker
I would like to express my special thanks to the Polymaker team for helping
in writing this chapter. Polymaker is an innovative company where research
and innovation are the core of the team and company growth. I joined
Polymaker in 2016 as a 3D printing engineer and kept growing my polymer
science knowledge to the point where I can start sharing with the 3D
printing community.
Polymers
In this chapter we will walk through the common issues and challenges
encountered in 3D printing with a material science approach. The idea
behind the chapter is to provide more scientific knowledge to common
issues in order to easily overcome them. Understanding this chapter can
help to prevent the need to reference elsewhere in this book.
To begin, it is important to understand what material is being used in 3D
printing: Polymers.

Polymers are large molecules, or “macromolecules”,

formed by large numbers of repeating units known as “monomers” in the
polymerization process. The polymerization process bonds the monomer
molecules together in a chemical reaction, forming the backbone of the
polymer.
The type of polymers produced can vary depending on the chemistry and
composition of monomer compounds that construct them. The links created
between the monomers will be defined as covalent bonds.
Polymers can be divided into 2 families: thermosets and thermoplastics.
Thermosets are polymers that are irreversibly cured from a soft solid or
viscous liquid pre-polymer into a solid polymer. The curing process is also
known as cross-linking, which proceeds via a chemical reaction that
connects all the monomers and pre-polymers to form a network structure. A
cured thermoset can no longer be melted and usually is not thermally
processable.

Thermoplastics are materials which become soft when heated and hard
when cooled. Thermoplastics can be heated, molded and cooled multiple
times with minimal change in their chemistry or mechanical properties.
Unlike thermosets where each of the polymer chain is linked to others with
a covalent bond, thermoplastics have their polymer chains linked with each
other with weaker links which will be defined as non-covalent bonds.
Polymers can also be divided into two main categories depending on their
micro-structure:
Amorphous and Semi-Crystalline
One of the ways that different thermoplastics can be identified is through
their micro- structure, which can define the properties and behavior of the
polymer.
Amorphous

Amorphous polymers are identified for not having a long-range

ordering. This means that the polymer chains are randomly oriented.
Generally speaking, clear plastics are often made with amorphous
polymers, such as PMMA, PS and PC.
Semi-Crystalline

Semi-crystalline polymers are identified for having an ordered

structure with structural domains known as “crystals”.
Crystals are an ordered and tightly packed group of polymer chains.
Crystalline domains and amorphous domains co-exist in semi-crystalline
polymers, thus the “semi”. The proportion of crystallized areas is defined
by the degree of crystallinity. A specific characteristic of semi-crystalline
polymers is that this degree of crystallinity can highly affect their
mechanical and thermal properties.
Now that we have a better understanding of the material structure we will
dive into its thermal properties to understand its behavior as a function of
the temperature. In order to do that, we first need to define the test which
will reveal the thermal properties of a polymer: DSC.
DSC definition
Differential scanning calorimetry (DSC) is a type of thermal analysis in
which a specimen is placed within a chamber and the amount of heat
required to continually increase the internal temperature of the chamber is
measured. This form of analysis is designed to pinpoint the temperatures at
which the specimen undergoes certain state transitions e.g. Glass transition,
crystallization, and melting, by documenting how a polymer reacts to the
gradual heat increase via its level of energy absorption and release.

Glass transition temperature (Tg)

The glass transition temperature can be found in all polymers, it refers to
the temperature at which a polymers physical state transitions from glass
(hard & brittle) to rubbery (soft & flexible). The Tg is usually used to
highlight the highest working temperature of an amorphous polymer.
Crystallization temperature (Tc)
Crystallization happens between Tg and Tm (melting temperature). It is the
process of polymer molecules aligning to form crystals. The crystallization
temperature is the point at which the polymers crystalize at the highest
speed.
Melting temperature (Tm)
The melting temperature is the point at which the crystalline domains of a
semi- crystalline polymer starts to melt/deform. Amorphous polymers do
not have a defined melting temperature.
Decomposition temperature (Td)
The decomposition temperature is the temperature at which a material
begins to deteriorate, meaning that the backbone of the polymer begins to
break down.
Notes about the above graph and definitions
A simple way to understand it is that the heat(energy) injected in the
chamber will be used to increase the internal temperature, however if the
sample (polymer) inside the chamber absorbs some thermal energy for
structural realignment, more heat will be needed to be injected to
continuously increase the temperature at a constant rate.
Referring to the graph above, at the beginning a constant amount of heat is
applied to the system to increase the temperature at a certain rate. At Tg
(glass transition temperature), we can notice that more heat is required to
increase the temperature at this same rate, this is because the sample will
absorb some thermal energy to break its non-covalent bonds and make the
polymers move more freely (resulting in the material becoming soft).
After this phase transition, the sample will have a higher heat capacity, so
the system will still require a constant amount of heat to be injected to
increase the system temperature at the same rate, but this amount will be
higher than before Tg. The energy continuously absorbed by the sample
will make the polymer microstructure move more and more freely (excite
them). At Tc (crystallization temperature), the polymer chain of the sample
will have enough free movement to form crystals. The sample will then
release energy (heat) which means that we need to inject less heat to the
system to increase its temperature.
The reason is that the crystals structure (a more ordered structure) is coming
from a more disordered structure, which will require less energy, thus the
release of the extra energy. Once the crystals are formed, no more energy
will be released from the sample to the system. However, soon after
creating the crystals, at Tm (melting temperature), the polymer chains will
continue gaining energy(movement) which will excite them too much and
make them break the crystal structure, thus absorbing energy from the
system, thus needing to inject more energy in the system to continue
increasing the temperature at a constant rate. After breaking all the crystals,
the sample will not require any additional energy from the system. This
explains the two opposite spikes at Tc and Tm. At Td (decomposition
temperature), the sample will start to decompose, meaning that covalent
bonds will start to be broken, the sample will lose its heat capacity and thus
less heat will be needed to increase the system temperature.
Warping, Oozing and Overhangs
Now that the thermal transitions and behavior of polymers in function of the
temperature are better understood, we can use this knowledge to explain
some of the 3D printing phenomena:
Warping, Oozing and Overhangs.
Before jumping into these phenomena, we need to clarify an important
point regarding printing speed and printing temperature:
Usually printing temperature is defined as the heat block temperature (in
˚C) and the printing speed will always define the print head speed when
printing (in mm/s).
In this chapter we will refer to more useful factors for us such as the
extrusion temperature and the extrusion rate:
Extrusion Temperature: The temperature at which the plastic exits the
nozzle (in ˚C)
Extrusion Rate: The rate at which the plastic is extruded from the nozzle
(in mm3/s)

The extrusion temperature can be increased using different factors:

Increase the printing temperature, reduce the printing speed, reduce the
layer height, or increase the nozzle heated chamber length.
The extrusion rate can be decreased using different factors:
Reduce the printing speed, reduce the layer height, or reduce extrusion
thickness.
Warping
In 3D printing, occasionally we will encounter a part that deforms on the
printer, curls or lifts up from the bed because of what is known as warping.
This is caused by the accumulation of stress created by the 3d printing
process.
The origin of the internal stress is still under debate, and depending on your
3D printer configuration, many factors may be contributing to the as-built
internal stress. Here is one hypothesis which should be considered for all
FDM machines:

During the extrusion process the polymer is forced through a die (small
hole/nozzle), and during this step the polymer chains will be stretched to a
stress state, then stuck to the build plate or a previous layer of plastic. This
stress will slowly be released over time, however if the temperature does
not allow the polymer to freely move enough to release the stress, or if the
layer is not well stuck to the bed or the build plate, the accumulation of this
stress throughout the layers will force the part to macroscopically deform.
Warping and cracking is always representative of this accumulation of
stress exceeding the bond between the bed or layer adhesion.
As a result, we have three ways to prevent warping/cracking:
1. Give polymers enough energy to move freely and release their
internal stress.
Most of the stress release happens right after the extrusion, indeed the
material will be extruded at a high temperature then cooled down below Tg.
It is during this time above Tg that the polymer will release most of its
internal stress, however if this time is too short, it will not have time to
reach equilibrium. Increasing this time period is a way to reduce warping.
This time period can be increased with the following ways:
Increasing the extrusion temperature (PT):

Increasing the room or chamber temperature (RT):

Decreasing the cooling rate:

2. Improve bed or layer adhesion

The accumulation of stress will tend to lift up the layer from another layer
(delamination) or the bed (warping). However, if the bed/layer adhesion is
strong enough to resist the deformation, the polymer will be able to release
its stress without deforming the part. The bed adhesion can be improved by
using adequate bed surfaces and coating (refer to the “Bed Adhesion”
chapter).
Before talking about how to improve layer adhesion, let us have a look at
what layer adhesion is:
Layer adhesion is possible thanks to the entanglement between polymer
chains from one layer to another.

This entanglement is possible when both layers are

heated up above Tg and both layers have their polymer chains moving
freely, and through this movement the chains entangle with each other.
To improve the layer adhesion, we have to increase the number of
entanglements between the polymer chains at the layer interface. The
number of entanglements can be increased by increasing the time where
both layers are in contact with each other with a temperature above Tg. As
we can see this is the same solution as number 1. However, an extra factor
which can improve the layer adhesion is increasing the contact surface
between the layers by increasing the extrusion width.
3. Reduce stress creation
This third solution to solve warping relies on reducing the root cause of
warping: internal stress.
As mentioned earlier, the stress is created by forcing the material through a
die which will create a velocity curve which will stretch and align the
polymer chains. Reducing the stress creation relies on flattening this
velocity profile. This velocity profile can be flattened by increasing the
nozzle size, reducing the extrusion rate, decreasing material viscosity (by
increasing the printing temperature) or coating the internal nozzle surface
with low flow resistant surface.
The above explanation of warping can be applied to amorphous and semi-
crystalline polymers. However, semi-crystalline polymers face an additional
source of stress: crystallization.
Indeed, when printing, the part will undergo crystallization when cooling
down creating small crystals which, as ordered structure, take less space
and will force the part to shrink. This is why Nylon materials will warp
even though the build plate may only be 45 degrees. If the crystals are
formed too quickly, each layer will have small crystals creating a lot of
stress per layers and the accumulation of this stress will macroscopically
deform the part.
Oozing
In this part we will differentiate two kind of oozing depending on the root
cause.
The first root cause is oozing created by the extruded filament being linked
with the material inside the nozzle. The extruded filament will then force
the material inside the nozzle to stretch out of the nozzle as the nozzle is
moving to another location. We will rename this phenomenon as stringing
(because of this string created).
Polymers with a high molecular interaction, or polymers which have
absorbed moisture tend to have this issue.
A simple way to solve this stringing issue is to cut the extruded filament
from the material in the nozzle by performing a wiping movement with the
nozzle before moving the nozzle to another location.

The second root cause is the actual material oozing created by the residual
pressure and gravity which will force the material out of the nozzle over
time.
As mentioned, the above 3 factors will define the amount of material oozing
out of the nozzle:
Residual pressure, gravity and time.
In order to reduce oozing, we will need to decrease or counter each of them:
Residual pressure:
Residual pressure is a result of the printer building up pressure within the
nozzle to extrude at a certain volumetric speed. This pressure can never be
completely discharged from the nozzle over a very short period of time and
therefore the material will keep extruding slightly. To decrease the residual
pressure, we can increase the retraction settings (distance, speed), increase
coasting (using the residual pressure to finish the layer), decrease the
extrusion rate (need less pressure to extrude) or increase the printing
temperature (need less pressure to extrude).
Gravity:
Gravity will always pull the filament out of the nozzle, and if the
gravitational force is stronger than the flow resistance of the plastic against
the nozzle’s internal surface and shear within the plastic, it will ooze out.
Note that the flow resistance between the internal surface of the nozzle and
the plastic can be increased by increasing the die L/D ratio (L: length of the
die capillary, D: diameter of the nozzle hole). The shear within the plastic
can be increased by lowering the temperature of the nozzle (thus the stand-
by temperature in several dual extrusion 3D printers).
Time:
The amount of material oozing from the nozzle also depends on the amount
of time the nozzle is inactive. The greater the duration, the larger amount of
material there is. This time can be significantly reduced by having high
travel speed, acceleration and reasonably high jerk settings. The material
will not have time to ooze out before reaching the other part of the model.
Having a high travel speed and acceleration should not affect ghosting as it
would with increasing the print speed and acceleration. However, for dual
extrusion printing, this factor cannot really be changed.
Overhangs
Although it is recommended to use support for overhang angle, it usually
saves time and material to being able to print high quality overhang
surfaces.

The challenge when printing overhang surfaces is the amount of actual

unsupported area. As you can see above, the same angle can give different
unsupported area depending on the layer height. It can appear that the
smaller the unsupported area the better, however the smaller the layer height
the less rigid the unsupported area will be. It will always be a balance
between rigidity and amount of unsupported area. You can visualize this
relationship through one of Sean’s videos titled “How to Avoid Needing
Support Material” on YouTube.
Different factor can affect the overhang surfaces. As represented on the
graphic below two main forces will be applied on the unsupported area: its
weight (F1) and the polymer stress (F2).
The main factors affecting theses forces is summarized below, however
generally speaking the best overhang surfaces will be given with a high
layer height (more rigidity), low printing speed (more consistent extrusion)
and high extrusion rate (more consistent extrusion).
Mechanical Tests
Before closing this chapter, it can be useful to also learn about the different
mechanical and thermal properties which can define a polymer. These 3
tests can determine how “strong” a material is depending on the application
you require from your print. CNC Kitchen on YouTube has some great tests
of 3D printed parts with the below methods.
Let us first review the 3 main mechanical tests:
Tensile testing

The tensile testing is where a polymer specimen is

subjected to tension until it breaks. The test can be used to determine a
specimen’s tensile strength, Young’s modulus, and elongation at break.
Charpy impact test

The Charpy impact test is the process of

measuring the amount of energy upon impact that is required to fracture a
test specimen. For plastics, the IZOD impact test is more commonly used,
but they are similar. This test is conducted by fixing an appropriate polymer
specimen in place and releasing a pendulum with a set mass at a set height
to collide with the test specimen.
Three-point flexural test
 Three-point flexural test is the measurement of a
specimen’s resistance to deformation under a gradual load. The test samples
are subjected to significant tensile and compressive stresses in their plane in
addition to shear stresses. This test can be used to determine the bending
strength and bending modulus.
Each of these tests will give important data which will define the material
performance:
The tensile strength will give a graph similar to the below one:

Tensile strength:
Tensile strength characterizes the maximum stress required to pull the
specimen to the point where it yields or breaks. Tensile strength at yield
measures the stress at which a test specimen can withstand without
permanent deformation, tensile strength at break measures the stress at
which a test specimen breaks, and the ultimate tensile strength is the
maximum between both. This allows us to understand the limit of a
materials strength and its behavior when under stress. Tensile strength at
break is not that common to use since the part has already started necking,
usually only yield strength and ultimate tensile strength are of interest.
Elongation at break:
Elongation at break measures the deformation ratio between initial length
and increased length right before breakage. This allows us the see the
amount of stretching a material can endure before breaking.
Young’s modulus:
Young’s modulus measures the resistance of polymers to deformation under
stress along a single axis. The Young’s Modulus is a material property that
is used to calculate the stiffness of a structure.
The bending strength will give a graph similar to the below one:

Bending modulus
Bending modulus is a local physical property that is computed as the ratio
of stress to strain in flexural deformation. The Bending modulus has
similarities to Young’s modulus as it tests the polymers ability to resist
deformation.
Bending strength
Bending strength represents the highest stress experienced within the
material at its point of yield or break.
Charpy impact strength
The charpy/IZOD impact tests measures the amount of energy that is
required to fracture a material sample under a sudden load/impact. During
the test the potential energy of the impact hammer is converted to kinetic
energy. A part of this kinetic energy is absorbed by the sample during
impact, so the hammer will not swing as further up as in the beginning. The
difference between the initial potential energy and the potential energy of
the hammer after the impact is the impact energy. This value is put into
relation to the reference area of the sample that broke to calculate the
impact strength (kg/m²).
Thermal Properties
Heat deflection temperature:
Heat deflection temperature is the measure of the temperature at which a
polymer undergoes a certain amount of deformation. The test is conducted
using a specific load, while steadily increasing the temperature by 2 °C/min
and measuring the temperature once the displacement of the contact sensor
of the specimen reaches 10mm.

Vicat softening temperature:

Whilst comparable to HDT, the Vicat softening temperature differs by
providing a testing method that simulates the point at which temperature
softens the material’s physical properties enough for an external object
under a set pressure to penetrate the outside surface of the specimen by
1mm.

Melt index:
Melt index characterizes the flow behavior of a polymer under a set
pressure and temperature. This is achieved by extruding the polymer and
measuring the total weight of the extrudate in a set time-period. The more
material that extrudes, the increased weight and therefore the lower
viscosity.
Polymaker Technologies
Now that we have more material science knowledge it will be easier to
understand the different technologies that Polymaker is using in their
products to help combat some of these material limitations:
Jam-Free™ Technology:

To understand this technology, let us

understand the main root cause of jamming issues:
The print head is divided in two main parts: the hot end and the cold end.
The hot end is where the heat block will heat up and melt the filament, the
cold end will prevent the heat from the hot end to disperse and damage
other components or soften/melt the filament before it needs to be.
However during long prints, dual extrusion prints and simply with a badly
design heat sink the heat will climb up to the cold end and soften the
filament which can lead to filament expansion thus jam, or the extruder
chewing the filament (which we call “heat creep” in the “Nozzle Clogs”
chapter).
PLA is the most concerned by this issue because it has a very low Tg
(~60˚C) so if the temperature raised a little bit over 50˚C, it can already
create a risk of jam. 2.85mm filament is less concerned by this issue
because they are thick enough to stay more rigid than 1.75mm.
To solve this issue, Polymaker increases the heat resistance temperature of
their 1.75mm PLA based product to 140˚C.
Since PLA is a semi-crystalline polymer, Polymaker is able to do this by
annealing the filament first, which will increase the crystallinity degree of
the filament. As we explained earlier, the crystal will start to break at Tm
(~150˚C for Polymaker PLA) so it provides more heat resistance to the
material.
Warp-Free™ Technology:
This technology is used by Polymaker in their PolyMide™ family (Nylon
based material). We already learned a lot about warping issues and potential
root cause earlier in this chapter. This technology solves one of the root
cause of warping issues: Crystalization.

Indeed, Nylon is known as challenging to print because of its warping

behavior, because when printing, the quick formation of crystals within
each layers will create a lot of internal stress - resulting in part deformation.
Polymaker’s technology is not only reducing this stress, but it is increasing
the mechanical properties of the part. The technology slows down the
crystallization rate of the polymer, which prevents it from quickly forming
small crystals within each layer as they are printed. Instead, it allows the
polymer to slowly build big crystal across layers, since multiple layers have
time to be printed before the formation of crystals. These crystals across the
layers will also significantly increase the inter layer adhesion. This is also
the reason why Polymaker will recommend to anneal the part after the
printing process. Annealing ensures the part has reached its highest degree
of crystallinity, providing the best thermal and mechanical properties.
You can see how strong this nylon can be by watching Sean’s video titled
“Nylon Comparison Part 1” on YouTube.
Layer-Free™ Technology:
This technology involves less of polymer science but more a perfect
combination of the right material with the right solvent. Polymaker was
interested in the smooth results that an acetone bath could give to an ABS
print, however they thought that the ABS was too difficult to print, and the
acetone could be a dangerous chemical and not safe to use. And there were
no actual devices which were designed for the purpose of using this solvent
to polish an ABS part (as you can tell in Sean’s “Post-Processing” chapter,
he used to use a crock pot).
The first challenge for Polymaker was to find a polymer which could be
easy to print and also react with a solvent which could be sourced easily and
less dangerous than acetone.
Polymaker finally found PVB as the perfect candidate. From there they
started to develop specific material formulas PVB based and PolySmooth™
was the results of this development.

PolySmooth™ could be printed with the same settings as PLA and could
then be smoothed with alcohol.
The second challenge was to design a device which could safely and
reliably polish a PolySmooth™ model using alcohol. The Polysher™ was
the result of this device development. The core of the Polysher™ being the
nebulizer, the carefully chosen membrane and the specific algorithm
developed to find the right frequency for the nebulizer.
Sean has a few videos on the PolySmooth™ going over its possibilities
titled “Polysher by Polymaker Review – Smooth your 3D Print”,
“Transparent 3D Prints”, and “More Transparent 3D Print Tests”.
Ash-Free™ Technology:

This technology is used in Polymaker Polycast™. It uses a specific

combination of different precisely chosen components to create a material
for casting. These components are carefully chosen to burnout without any
residues.
Fiber Adhesion™ Technology:

Fiber reinforced materials provide excellent

thermal and mechanical properties, however in extrusion based 3D printing,
it can negatively affect the layer adhesion. Polymaker believes that the layer
adhesion issues come from the fibers not bonding/matching well with the
matrix polymer.
After months of development, they successfully optimized the surface
chemistry of the fibers to achieve better dispersion and bonding to the
matrix.
When implementing this technology to PolyMide™ PA6-CF and
PolyMide™ PA6-GF, the layer adhesion was not negatively affected, but
actually stronger (+27% for CF, +15% for GF).
Nano-reinforcement Technology:

This technology is used in Polymaker’s

PolyMax™ family of products. It reinforces the polymer with nano-
particles that make it much tougher, while simultaneously keeping similar
printing conditions. PolyMax™ PLA, PolyMax™ PETG and PolyMax™
PC are the 3 products from the PolyMax™ family. They all print with the
same settings as their regular counterpart: PolyLite™ PLA, PolyLite™
PETG and PolyLite™ PC, however they can achieve up to 5 times the
toughness, making them more durable.
As reviewed earlier in this chapter, the fracture toughness can be well
represented by the impact resistance of the material.
Stabilized Foaming™ Technology:
This last technology is one of the earliest developments by Polymaker.
After several bad experiences clogging nozzles with printing wood filled
filament, they thought about ways which could make a filament look like
wood without actual wood powder in it, since wood powder in the filament
could negatively affect the printing process.

Polymaker realized that the main reason

for the appearance of wood was its plant cell structure and color. It was easy
to copy the color of a certain wood, and the plant cell structure was copied
using a foaming agent, creating a similar cell network.
The main challenge was to design and formulate a foam structure which
would not be negatively affected by the extrusion process of the 3D printer,
thus the “stabilized” in “Stabilized Foaming”, meaning that the foam will
remain stable after the printing process. They have finally developed
PolyWood™ from this technology.
Missing Layers

This is an issue that occurred for me randomly and I had a lot of trouble
diagnosing it. I actually have a video on this titled: “Diagnosing and Fixing
an Unknown 3D Printing Failure” on my YouTube Channel. This problem
can also be known as “temporary under extrusion”.
Replace poorly made extruder
If you were to watch my video listed above, you would find out that
replacing my extruder is what finally fixed this issue for me. This is not an
ideal solution, but I was using a home-made Greg’s Wade extruder, which
likely had tolerance issues and may have worn down over hundreds of
hours of printing.
If you are using an extruder that you personally made, or one that is made
with lack luster tolerances, I would suggest changing it. As mentioned
elsewhere I have standardized to the Bondtech BMG extruder, which I think
is well-worth the $100 investment if you plan on 3D printing a lot.
At the minimum you should replace any home-made or plastic extruder
with a metal one made by a reputable manufacturer if this problem is
occurring (which can be found for under $20 for non-geared). TH3D sells a
great metal upgrade extruder for Creality style printers for only $14, which
should drastically help with this missing layer problem if you do not wish to
buy a geared extruder. You can always reprint your home-made extruder
parts after fixing this problem if you wish.
Check for extruder skipping
One of the main reasons this will occur is if your extruder motor is
skipping. I have a chapter on this topic, so you will need to read that if your
extruder is skipping and making a “clicking” noise.
Extruder Idler tension
The idler on your extruder is what is creating the tension on your filament.
Some basic extruders may not have one, but all extruders will have some
form of spring that puts tension so that your filament is held tightly between
the threaded bolt and the bearing (or both threaded bolts for dual drive
extruders).
Confirm that the filament is held tight so that no slipping can occur. One
reason for missing layers is that the filament is not held tightly enough.
Turn up your extrusion temperature
This can happen on a print when your hotend isn’t hot enough for the
particular material you are printing. The PLA I normally use has a
temperature range of 205-220 degrees Celsius, and I almost always print at
the higher range, right around 215 degrees. I experienced this issue once on
my main printer with upgraded parts since I was printing at 205 degrees.
Right when I bumped this back up to 215, the issue went away.
Printing at too low of a temperature for your material can cause too little of
filament to extrude. And this can happen at random times during your print
rather than throughout, since the hotend doesn’t have enough time to heat
the material when going at its top speeds. This would result in temporary
under extrusion and missing layers.
Slow your print down
Just as with running to low of a temperature, you can be feeding your
filament too fast for either your extruder or your hotend.
When working with a stock non-geared extruder, along with a stock hotend,
I wouldn’t run my printer any faster than 45mm/s, no matter the material.
With my upgrades I can easily print 60mm/s or higher, but whenever I run
prints on a stock lower end machine, I decrease this to 45mm/s or less. If I
am experiencing any issues, I go closer to 35mm/s.
This is a common solution to many problems in this book. Slowing your
printer down can not only help you to diagnose particular problems, your
printer may actually require you to slow down. Don’t always believe
manufacturers advertised printing speeds.
Make sure your fan isn’t dropping your
printing temperature
If your active cooling fan is blowing onto the heaterblock and nozzle, rather
than right below the nozzle, you can experience your extrusion temperature
dropping in the middle of your print. Since we said that having your
printing temperature too low can lead to this problem, your active cooling
fan dropping the temperature can be the culprit as well.
Always use a silicone sock if possible on your heaterblock, since they will
help to prevent any fluctuation. I use them on every one of my E3D hotend
prints. If possible, re-print your active cooling fan to one that blows
downward and wraps around the nozzle. Search on thingiverse and
elsewhere for a file if you are unable to design one yourself.
Be sure to read the “Hotend Can’t Reach or Maintain a Temperature”
chapter if this is occurring for you, since there are a few solutions including
running a PID autotune.
Filament diameter problems
You should always confirm that your filament diameter in your slicer
settings match what you have on your spool. This should always be set to
either 1.75mm or 2.85mm, since those are the only two standards used in
3D printing.
That said, your particular manufacturer of filament may not have very tight
tolerances. The tolerances of materials can be anywhere from .01mm to
0.1mm.
You can use calipers to confirm the average diameter of your material, but
in all honesty, I would just suggest going with a more reputable
manufacturer with tighter tolerances. Most reputable manufacturers produce
filament with tolerances between .03mm and .05mm these days which is
adequate for most prints.
Potential under extrusion
For this particular issue, I would assume under-extrusion isn’t the main
problem, but it could be adding to your problems. Since having a missing
layer is temporary under extrusion, the rest of your print should be
extruding properly.
Check your E-steps, just as explained in the “Over and Under Extrusion”
chapter. This likely wouldn’t fix the problem by itself, but the symptoms
may be reduced.
Re-slice your part
If this is happening across multiple prints, then obviously re-slicing won’t
fix your problem. But if you are only using the same G-code, and the
problems keep occurring at the same layer, it is worth your time to re-slice
and export new G-code.
Before exporting, go into the layer mode of your slicer and analyze. I have
actually had in the past where you can see the missing layer right in the
slicer. This was due to a model error, and after fixing it, the slicer then
showed that layer being printed.
Check your rods/rails, bearings/rollers,
and lubricate
Be sure to look up and down your printer to see if there are any issues, and
perform a full maintenance check as explained in the “Mandatory
Maintenance for 3D Printers” chapter.
One thing that chapter details is for you to lubricate your rods. This
obviously isn’t needed on rail systems, but all rods should be lubricated for
bearings to move easily.
With your stepper motors disabled, move your hotend and build plate
around its axis and check for any rough spots or where there is more friction
than others. If there are rough spots, then you will need to lubricate, check
your frame for any bends or misalignments, confirm your build plate
corners are tightened too tight, and make sure your bearings/rollers aren’t
broken.
You may need to replace your bearings and/or re-align your frame to make
sure everything moves freely.
Extruder motor overheating
While this has never personally happened to me, I can only assume that
your extruder motor, or stepper driver, overheating can lead to temporary
under extrusion.
When stepper motors or stepper drivers overheat, they will not turn or work
until cooled down to a working temperature. If this happens on your stepper
motor, then it won’t turn properly, under extrude, and then kick back on.
Your extruder stepper is working harder than any other axis, since it is
under very high loads when forcing filament through the nozzle. You
always want to make sure that you have a heatsink attached to the motor,
and a small one attached to your driver on your board.
Refer to the “Stepper Motors Overheating or Malfunctioning” chapter if this
is happening to you for a full fix.
Old filament
As explained elsewhere in this book, old filament, especially those that
have absorbed moisture, can lead to some confusing issues. If you have
tried everything else, it might be worth just trying a different spool to see if
your problems are alleviated.
Summary of Fixes and Precautions
Replace a cheap or poorly made extruder.
Check for extruder motor skips, and refer to that chapter if
occurring.
Turn up your extrusion temperature to closer to the top of the
recommended range.
Slow your print down, especially when using a stock non-geared
extruder.
Confirm that the printer isn’t dropping temperature mid print due to
the active cooling fan.
Confirm you are using the correct filament diameter, and that you
are using from a reputable manufacturer tight tolerances.
Check your e-steps as to not exasperate the problem.
If occurring on one model, make sure to re-slice and examine the
layers mode to see if the slicer is showing the problem.
Do a physical mechanical check of your printer and perform all
important mandatory maintenance.
Make sure your extruder stepper or stepper driver isn’t overheating.
If so, refer to the “Stepper Motors Overheating or Malfunctioning”
chapter.
Try again with new filament that hasn’t absorbed moisture.
Model Errors
I am personally not a designer, nor am I extremely familiar with all the
designing software out there, so I am not the best for giving advice when it
comes to combining parts and properly exporting them in your preferred
program. That said, there are some common issues that come into play with
models exported for 3D printing.
Holes, one sided walls, and other model
errors
Other than the problems described below, there can actually just be errors
within your model itself. This is extremely common if you used SketchUp
to do your designing. I do not have the exact reasoning for this, but it seems
to happen with .STL’s exported from SketchUp more so than any other
program.
Someone who takes all of the proper steps to design a model for 3D
printing, including combining and exporting properly, should never
experience a model with errors. But there are some free and paid programs
out there that can help you diagnose and fix model errors.
I personally use the free version of Netfabb Basic. This actually isn’t
available any longer (at least without some hunting on GitHub), but there is
the ability to fix models via Cura. Below is an example of a model missing
a face and being too thin to print since it is not solid.

When you open

up your settings you are given “Mesh Fixes” as a settings option. You can
play around here and go back and forth from layers view to see if your
problem was corrected.
 If you are able to
download a previous version of Netfabb, this is also very easy. I was able to
download this old version via some hunting online and finding a version of
Netfabb Basic on GitHub. When you bring an .STL into Netfabb, you will
see a red exclamation mark telling when there is a model error. You would
then click on the “Repair” button up on the top toolbar
Choose “Automatic Repair”, execute the default repair, and then click
“Apply Repair”. This fixes the vast majority of model errors so that it can
be 3D printed.
If you still see the exclamation mark after attempting this repair, or you
can’t figure out how to download Netfabb Basic, you can also try out
Microsoft’s free online model repair tool at tools3d.azurewebsites.net.
There are likely other free methods to fix models, such as using
MeshMixer, but I personally do not use those.
If you are still experiencing issues, you may need to redesign or re-export
the part.
Parts that are not actually 3 dimensional
A common practice for those who do not have much designing for 3D
printing experience will be to take a 2D object and fold it around itself.
If you were to take a 2 dimensional rectangle and then fold it around itself
so that it is a cylinder with an open top and bottom, the object will look 3
dimensional to the human eye, but will not be recognized as such by the 3D
printer or slicing software.
This is because the object you are looking at has walls that are infinitely
thin – they do not have any actual depth to them.
You will need to close off these objects and make them solid, or do some
other designing practices that allow them to become actual 3 dimensional
objects with solid walls.
Wall thickness
These next few may not be considered a technical error in the model, but
essentially result in the same problems. You will always need to consider
the thickness of the nozzle diameter you are using when designing the
thinnest part of your print.
An FDM 3D printer can only print walls that are at least as thick as the
nozzle diameter (or rather, the line width). I personally almost always print
with the same line width as the nozzle diameter, though I have been
experimenting with increasing it by 10% lately.
I normally suggest walls be at least 2-3x as thick as the nozzle diameter/line
width, but the absolute minimum requirement is the diameter/line width
itself. So, if you were using a 0.4mm nozzle (with 0.4mm line width), but
some of the walls on your print are 0.3mm thick, those walls will not be
recognized, and therefore will not print.
Along with increased detail, a smaller nozzle will allow you to print walls
that were not visible on nozzles with larger diameters. You can always see if
your walls are recognized by your printer by checking the “layer mode” in
your slicing program.

In the example
above, the tips of Old Man Logan’s claws (designed by Exequiel Devoto on
MyMiniFactory) are thinner than 0.4mm – the diameter of the nozzle I was
using. Increasing the size of this part will allow you to print more, since the
diameter of the blades will increase. If you are unable to print larger, you
will need to use a smaller diameter nozzle.
If something is thinner than the thinnest diameter nozzle available, you have
a part that cannot currently be FDM 3D printed. I have further information
on the pros and cons with printing in small diameter nozzles in a video
titled, “3D Printing with Extremely Fine Nozzles”.
Unprintable models
A model can be considered unprintable for many reasons, one of which
being it requires support material that is impossible to remove. This is also
explored in the “Limitations Involved with 3D Printing” chapter at the end
of this book.
If you were to design a hollow cube with a single small hole giving you
access to the inside, you will likely never be able to print this model.
This is because a cube of any decent size will require either infill (not
hollow), or removable support material. If your hollow cube does not give
you access to the inside, you will not be able to get that parent support
material out. The other option would be to attempt to bridge the large gap,
but no printer or material will be able to bridge 100mm+. This is why this
hollow cube may be possible if small, but just about impossible if large.

You can see this

a bit better with the above example. It would be just about impossible to
remove that support through the hole, but you wouldn’t be able to bridge
this large gap without support material.
While this basic model may have no actual errors, you will not be able to
print it successfully.
You can see my video titled “Cura Tricks for 3D Printing” where I am able
to print one of these unprintable models, but it was quite difficult and may
not work for all models.
Summary of Fixes and Precautions
Try to avoid designing on SketchUp.
Always combine parts and export them using the proper methods of
the program you are using. Do not cut corners.
Use Cura, Netfabb, MeshMixer, or a similar program to diagnose
and fix printing failures due to poor models.
Make sure the walls of your print are at least as thick as the diameter
of the nozzle/line width you are using.
Inspect your print in your slicing programs “layer mode” to see what
toolpath the printer will actually follow.
Always take note if you have the ability to remove the support
material that is being laid down.
Not Finding Home and Inverted
Prints
When you start a print your extruder and bed will go to its “home” position.
It does this by moving the carriages until hitting their respective endstops. If
there are any obstructions in the way of this process, or if there are any
malfunctioning endstops, you can run into some serious structural issues.
The other way this can happen is via your firmware being set up
improperly. If your printer is going to the incorrect location for home, you
may also be experiencing inverted prints. This should not be an issue on a
printer that you have not done any tweaks to.
Remember to refer to the “Diagram of a 3D Printer” near the beginning of
this book in order to know what and where endstops are.
Clear axis’s of any obstructions
Each axis and machine setup will come with different obstructions that can
prevent your printer from finding home. When this happens, your stepper
motor for that axis will continue to turn and skip even though it cannot
move any further. If this is on the X or Y axis, you may not experience any
long term damage to your printer, but when on the Z axis you can have a
nozzle that continues to dig into your build plate, resulting in issues to your
frame, nozzle, and possibly even cracking your bed.
The most common obstruction I have experienced when dealing with a
printer’s X axis is when I leave the extruder idler open and start a print
(which isn’t possible with all extruders). This particular idler is just long
enough to run into the printer’s frame before engaging the endstop, causing
quite a lot of noise when starting a print. You can also get an obstruction in
the X axis from tangled filament or an extruder setup that is unable to
engage the endstop.
For the Y axis, the most common obstruction seems to be wires and power
cords. Since the build plate remains at ground level during a print on a
Cartesian printer, and since it requires thick cords to power its heating, they
can get in the way during and after a print. Throughout a previous print
these cords may have gotten in the way of the build plate hitting its endstop,
and you wouldn’t know until you try to home or start a new print. You can
also get a Y-axis obstruction if the endstop is unable to be engaged due to it
being in a slightly improper position.
The Z axis really does differ on every machine and setup, but if you are
using a mechanical screw to check your Z-height, there is a possibility it has
been dislodged and not engaging the endstop. Confirm that the screw lines
up properly with its endstop and that it is able to engage it to the point that
the endstop clicks. This isn’t as much as a problem today as the past, since
auto bed levelers have become more common.
Clear any obstructions and confirm all endstops can be engaged when
homing before moving on to the next solution.
Malfunctioning endstop
A malfunctioning endstop is one that does not send a signal to the controller
(i.e. light up) when engaged (pushed down until it clicks). This could be due
to a broken endstop, or due to the wiring being disconnected.
First confirm that all wires are plugged into the end stop and board, and that
none have been pulled out from their connectors. Then check for any easy
to see visual issues such as frayed or burnt out wires. If you do not see any,
pull out your multimeter and check each wire for continuity, as explained in
the “Stepper Motors Overheating or Malfunctioning” chapter. If one wire
does not read out any noise or continuity, attempt to find where the break is,
cut and solder, or replace the wire entirely.
If all wires show connectivity, your endstop itself may need to be replaced.
Luckily, these are very cheap and I recommend having a spare on hand to
test and fix this issue fast.
Homing to wrong side or endstop on
wrong side
These next steps should only really be an issue on a machine you are
building yourself. If this is occurring on a machine that was sent to you
from the manufacturer, it was likely their fault, and worth contacting the
manufacturer.

3D printers can have very different understanding

of where “home” is depending on the manufacturer. For some - home is
when the X carriage is all the way to the left and the bed is all the way back,
others it can be the exact opposite. CoreXY printers will have the bed
homing by either moving it up to the nozzle, or down to a specific set point.
Though this can vary, the standard for the majority of Cartesian (non
CoreXY or Delta) machines is having the nozzle home to the front left side
of your build plate (as pictured).
If you have your endstop on the incorrect side for where your machine is
homing, it will clearly never be able to find it. You will hear a lot of noise
as the extruder or build plate continues to try and move and cause your
stepper motor to skip.
If you are unaware of where “home” should be on your printer, it is a good
bet that it is where your printer moves to when starting a new print. If you
are sure that home should be on one side, yet your printer always moves to
the other, you may have your settings incorrect in either the firmware or
when slicing your G-code. You will definitely be able to tell if this is the
case if your prints are coming out inverted.
If your prints are not coming out inverted, it is likely easiest for you to just
physically change the location of your endstop. If you would rather go the
firmware route, open up Marlin when re-flashing your machine, and go to
the Configuration.h tab. Scroll down until you see “ENDSTOP
SETTINGS:” followed by each axis’s home direction being defined by
either 1 or -1. If the axis that is homing on the incorrect side for you, and it
says 1, change it to -1. If the axis’s that is homing on the incorrect side for
you says -1, change it to 1.
 Inverted
prints
If your prints are coming out inverted, it is normally when one of your axes
is inverted via firmware, slicing program, or your motor is wired/setup
improperly. You would really only need to change one of these regardless of
which was causing you this issue. If you setup your stepper motor on the
wrong side, so that it is turning your belt the incorrect direction, it will
likely be easier to just invert this axis in your firmware rather than
rebuilding that part of your machine.
To do this open up marlin to flash your machine. While in Configuration.h,
scroll down to where it says “#define INVERT_X_DIR” followed by either
true or false, and the other axis’s below it. Whichever axis is inverting for
you, switch the language (turn “false” to “true”, or vice versa).

If you are
currently homing properly, but your axis is inverted, you will want to
change the language on both sections of the Configuration.h tab mentioned
above. This will correct the inverted axis but still allow home to be in the
same location, meaning you do not need to relocate any endstops. If you
only change the invert, but not the endstop settings, you will be homing in
the incorrect spot.
When finished, plug in your machine, choose the correct board and port,
and upload.
Another option is to literally invert the wires going to your stepper motor in
question. If your wires are in the reverse order, the stepper will turn in the
opposite direction. This will of course change where “home” is, so you
should only do this method if you are homing in the wrong spot AND have
inverted prints.

Summary of Fixes and Precautions

Confirm that there are no obstructions from any axis hitting its
respective endstop.
Confirm that the endstop lights up when engaged.
If the endstop does not light up, check that all wires are showing
continuity. Replace any that are not.
If all wires show continuity, replace the endstop in question.
If homing to opposite side of your machine but parts are not
inverted, you can either physically move your endstop to the other
side or you can change the proper language in Marlin.
If homing to opposite side of your machine but parts are inverted,
change the proper language in Marlin.
If parts are inverted but you are homing to the correct side of your
machine, change both the language in both sections of Marlin
mentioned above.
Nozzle Clogs
Nozzle clogs are just what they sound like and are a fairly consistent
problem with FDM machines. They can take a very long time to fix and can
normally not be diagnosed until the print has been going for a while. Most
of the time these nozzle clogs will actually be clogs in the barrel, but we
will still refer to this issue as a nozzle clog. We can think of these as more
“filament clogs” where the filament is clogged somewhere in the hotend.
If the nozzle clog is frequently happening, even after doing these fixes, you
will need to review the “Settings Issues”, “Hotend Can’t Reach or Maintain
Temperature”, and “Hotend Not Reading Correct Temperature” chapters.
One way to help prevent nozzle clogs is to use an all metal hotend. Many
inexpensive machines do not come with an all metal hotend, and have
PTFE tube go all the way to the heat break. This can cause unwanted issues
and further nozzle clogs. An upgrade to an all metal hotend is not only
needed for printing at higher temperatures, but recommended to just avoid
nozzle clogs.
IMPORTANT NOTE: Anytime you switch filament you will ALWAYS
want to push the material down around 1 cm before removing. Some minor
heat creep can occur when the printer is cooling down after a print and is
only noticeable when you attempt to remove it. This practice can save you
from an untold amount of barrel clogs. I never change filament without
pushing some out before removing it.

Heat Creep (Ghost Printing Where You Cannot

Easily Remove the Filament):
 Heat creep refers to when heat creeps up the filament
and causes unwanted expansion. If filament within the barrel gets too hot, it
causes the plastic inside the barrel to heat beyond its glass transition
temperature, and will often create a little bubble. This bubble will cause a
ghost print where the printer continues to try and print, grinding filament,
skipping your stepper, and result in filament that you cannot remove.
Please keep in mind that this used to be a common issue for me, but over
the past year or two it has only happened a handful of times. If you take all
of the proper precautions outlined in this book, it should not become too
much of an issue.
Heat creep is far more common on materials with a low glass transition
temperature, since it allows the material to deform at a lower temperature.
Be sure to refer to the “Material Science” chapter in this new 2020 edition
for a further explanation on this, and how Polymaker has been able to work
out a PLA that doesn’t run into this issue.
If the heat creep is minor, you may be able to use a small Allen wrench to
push the filament through while the hotend is hot until it makes it past this
bubble, but you do not want to put too much pressure on your machine or
else you will cause extra problems for yourself.
When the heat creep is more excessive, you will want to disassemble your
hotend. If your filament hasn’t already grinded to the point where it has
snapped, you can break it off now. Disassemble as far as you can until you
are left with the section that will not allow you to move the filament. This is
normally in the barrel, but can be in the hotend itself.
If in the barrel, you will want to remove all plastic parts that may be
connected (fan, printed adaptors for your machine, Teflon tubing), and any
wiring that you can. There shouldn’t be any direct wiring to the barrel, but
you will need to remove any Teflon tubing from inside if using 1.75mm
filament. If you have an all metal hotend, you will then want to get a lighter
or a propane fueled torch. Be sure to not use a high temperature torch due to
the possibility of it melting your barrel. You can use a standard Bic lighter if
in a pinch.
Before proceeding I must warn that this is dangerous and should only done
at your caution. You will want to be in a very well-ventilated area and wear
a mask for your protection. Do not attempt this procedure if you do not feel
comfortable handling the following equipment. Use gloves and take proper
precaution.
Hold the barrel with a wrench or pliers that have rubber grips up to the
flame (while wearing the proper gloves). Doing this with a wrench that does
not have metal grips will cause the handles to get far too hot.
If possible, pinch the filament in-between another set of pliers with your
other hand. You can then carefully pull until the barrel gets hot enough that
the filament will melt and the material will be easily pulled or pushed
through. Clean out the barrel from remaining debris if you see any by
pushing a small Allen wrench through.
If the clog is in the unlikely section of your hotend, you will want to do this
same process, only you must make sure all wiring is out of the way or
removed. This type of clog is rarer because the hotend can normally heat
itself hot enough to push filament through without the need of a torch.
Be sure to allow the barrel to cool all the way down to room temperature
before reassembling. Once reassembled you can now move forward with
future prints, but be sure to read on to prevent this from happening in the
future.

How to prevent heat creep:

Since heat creep means that the temperature from the hotend is creeping up
the material, there are a few prevention tips that can be tried.
Confirm your barrel cooling fan is on and
not obstructed:

The majority of
hotends will have a fan that blows on the barrel of your hotend. I wire my
barrel cooling fan directly to the power output on my board so that it is
always on, something you may want to consider (and most manufacturers
have built-in). If this fan is not blowing or is obstructed by debris when
your hotend is heating, you will need to fix it in order to prevent heat creep.
The same is true if the fan itself has broken blades. Some of these fans do
not have shields over them, and I have accidentally bumped one or two in
the past with an Allen wrench. This caused a blade to break off and not
have as good of airflow – meaning a replacement fan was required.
First turn off and unplug your machine. Make sure your fan is of the proper
voltage for your machine (12v/24v) and that all the blades are intact. If you
have an extra fan of the proper voltage available, connect that fan instead
and turn back on your machine. If it works, you can skip the next section
since the issue was a burnt out fan.
If the above solution does not work, unplug and turn your machine off once
again. Inspect the wiring of your fan. You may easily see that a wire has
come loose or been disconnected. If you do not see a problem, you will
have to use a multimeter tool to check the continuity of the wiring from
your board to the fan. If one of the wires does not show continuity, you will
either need to re-solder the unconnected section, or rewire entirely.
This is simple on many machines, but can be quite a headache on others.
Having the proper connectors and ability to solder will make this process
exponentially easier. Be sure you see connectivity on the wire all the way
from your board to the fan, there are no exposed wires, and turn your
machine back on.
If the fan still does not turn on, there may be a problem with the section of
the board that that fan is wired to. With the machine unplugged and off,
wire the barrel fan directly to the power input section on your power supply
(red to + and black to -). Turn your machine back on, and if you are using a
new fan and new wiring, everything should be working again. If not,
reconfigure marlin and re-flash your machine for one final attempt before
possibly needing a new board (which shouldn’t be needed when wiring
directly to the power supply).
If you are using a stock Creality hotend, or something similar which has a
small barrel section, you will want to make sure the fan has enough airflow
to keep it all cool. Even though they are quiet, try to avoid Noctua fans.
Where you can purchase fans and other accessories are explained in the
“Important Accessories and Replacements” chapter, and links for which are
always at my website 3DPrintGeneral.com
Confirm you have a heat break in your
hotend
A heatbreak is a small metal tube that connects your heaterblock to your
barrel. This small part helps to have a break between the two as to disperse
heat and prevent your barrel from getting too hot. By itself without a barrel
cooling fan will not be enough, but it will definitely help in preventing heat
creep. The vast majority of hotends, including the common E3D variety that
I use, have these built in, but I have had an inexpensive machine not have
one. This inexpensive machine has a lot of problems with heat creep, even
though it has a barrel cooling fan.
Make sure you are not printing too slow or
too hot:
This will involve you checking the settings on your slicing program. If you
run your machine too hot, too slow, or a combination of the two, it will
allow heat to move up the filament easier. Try lowering the heat a bit or
speeding the print up to see if this helps with the problem. Normally
lowering the print speed will help to diagnose and fix issues, but when
combined with a very hot nozzle can create a bit of heat creep.
Reference the “Settings Issues” chapter of this book for further help with
tweaking your slicer settings for a more accurate print.
Swap materials
This really shouldn’t be needed if you are doing everything correctly, but
some manufacturers or old filament may be more susceptible to heat creep.
Check out Polymaker’s PLA where they have been able to make heat creep
impossible by annealing their PLA first.
Lubricate filament for all metal hotends
This one is a bit odd and new to me, but I have learned that the one issue
with all metal hotends is the fact that PLA is starch based filament, meaning
it will stick to the steel heat breaks when hot. This can add to friction and
potential clogging.
It would be smart to add a bit of lubrication for your filament if you are
experiencing hard to diagnose clogs on an all metal hotend. To do this
would just involve adding a small sponge to where your filament runs
through before going into your hotend. You would then add a drop or two of
Canola oil, or another similar oil.
This oil will then slightly rub onto the filament as it feeds into your hotend,
lubricating the heat break. The heat break will eventually get seasoned like
a cast iron skillet and not require further lubrication.
If you do not lubricate, you can have more frequent clogs, or just under
extruded parts.
Final attempts to fix:
If you have done everything above and are still experiencing heat creep,
you may want to invest in a new barrel or an entire new hotend. I have
personally used E3D hotends for a while, and while they do have an
occasional heat creep, it is not a consistent issue. Your barrel may have been
degraded over time causing the diameter of the hole to be inconsistent. Or
the company you may have purchased it from may not have the tolerances
and quality that other products guarantee. I have seen other makers cut an
E3D hotend in half and compare it to off brand Chinese cheaper products,
and you can easily tell the tolerances are much more precise on the name
brand E3D version. Sometimes you get what you pay for.
Finally, your thermistor may be reading the incorrect temperature. Though
very uncommon, your hotend may think it is 230°C, when it is actually
running at 250°C. To fix this issue, please refer to the “Hotend not Reading
Correct Temperature” chapter of this book.

Clog in the Actual Nozzle (ghost printing,

can’t push filament through but may be able to
remove the filament):
A clog in the nozzle and not your hotend or barrel is normally caused by
one of two issues: settings issues with the diameter of your nozzle, or
improper purging of the previous filament. You will want to treat a clogged
nozzle in the same way you would with a clogged barrel that I go into
further detail above: Remove the nozzle and carefully apply a torch in a
well-ventilated area until you can push the clogged filament through.
Remember to always remove and replace nozzles with the hotend set to
240°C due to the expansion of metal.
 Too fast
for the diameter of nozzle you are using:
It’s easy to understand that the larger diameter of nozzle you are using, the
easier it is to print without any clogs. E3D makes nozzles from as large as
0.8mm in diameter (up to 1.4mm in their SuperVolcano nozzles) all the way
down to 0.15mm. I have personally used every diameter of nozzle they
offer and can personally attest to the increase in nozzle clogs the lower you
go. It took me roughly two dozen failed prints on their 0.25mm nozzle
before I honed in the proper speed and retraction settings for this nozzle
diameter without any clogs or issues (mind you, since upgrading to the
Bondtech BMG extruder, the issues have plummeted) .
This meant that I torched out the nozzle quite a few times before I got
everything right, each time having to wait hours into the print before the
issue showed itself. I repeated this process with the 0.15mm nozzle, and
with each type of material. Once honed in, you should only use the same
manufacturer, since each company you purchase filament from may require
slightly tweaked settings, and these minor differences in settings become
more apparent the smaller in nozzle diameter you go.
There is no one step solution for this - you will need to manually tweak
your settings until you achieve a print without any clogging (though
upgrading your extruder may help). Refer to the “Settings Issues” chapter of
this book for further detail on how you may be able to fix this yourself. You
can always move up in nozzle diameter if you can’t seem to get things to
print properly. I have found that a 0.4mm diameter nozzle achieves very
accurate prints with very minimal issues of clogs, and a 0.6mm nozzle is
extremely easy to use and fast to print, but not the greatest when it comes to
X/Y accuracy of text and other detail.
If you want to print really fast with large nozzle diameters – you will need a
hotend that allows for this, such as the Volcano setup by E3D. This is
because the standard hotend does not allow enough time for the material to
heat up when extruding so fast – something the Volcano compensates for.

Filament Grinding (ghost printing and you

can remove the filament and push it through again):
The filament will often grind to the point of snapping with the two
possibilities above, the difference here being there is no heat creep requiring
you to disassemble your machine. You can just use some pliers to remove
the filament, reload the material, and push everything through without any
clogs.
When this failure gets extreme, it can lead to you needing to read the
“Stripped Filament” chapter. This is likely due to having too much moisture
in the material.
If you are using flexible material, you may see the filament curled up before
it grinds. Make sure you slow the print down if this happens, and confirm
you have an extruder with enough torque for flexible material. Also confirm
that there is a straight, clear path through the hotend. Bowden machines
cannot print many flexible materials, even when using a strong geared
extruder. The longer the tubing run between your extruder and hotend, the
more difficult it will be to print with flexible materials.
While the cleanup is easy, you are still left with a failed print. If you just
click “re-print”, you will likely end up with the exact same results.
How to prevent filament grinding:
Loose or tight idler tensioner, blockage, wrong hot end temperature, and too
fast of retraction and print speeds are all common causes, yet easy to
correct. The one that is the most annoying is from having too much
moisture in your filament. Make sure you also read the “Stripped Filament”
chapter in this book.
If you were to speed up your machine 10x what it normally prints at, you
can imagine how your extruder gear would be turning far faster than
material can be pushed out the nozzle. This would cause the filament to
grind until the point of snapping (if not just causing your extruder motor to
skip).
Before clicking re-print, try slicing your part with both your print speed and
retraction speeds slower. Watch the print and see if there are any sections
where the extruder is moving too fast, and attempt to fix in your slicing
program or by turning the knob on your LCD screen. The general rule of
thumb is to limit the maximum print speed to 100x the nozzle diameter,
printing at no greater layer heights than 75% of the nozzle diameter. The
print speed maximum is a starting point, and with a good geared extruder on
a well-built frame you can get closer to 175% print speed compared to the
nozzle diameter.
Next, adjust your idler tension. Start by loosening the idler and then feed
filament through and tighten until you no longer experience slipping, but
not so tight you experience grinding or stepper motor skipping. Filaments
vary in diameter, so although the idler will absorb some variations, some
material will require fine adjustments. I have my idler extremely tight on
my Bondtech BMG since the grip and torque on that are good enough
where I do not experience extruder motor skips, but you will have to find a
happy medium with a less powered extruder.
You should also check the temperature you are running your hotend at and
make sure it is not running too cold. If you try to print ABS at 200°C, you
might be able to get some filament to extrude at first, but it will eventually
get stuck. If slowing your printer down didn’t help, try increasing the
hotend temperature a bit (which is the opposite advice given for heat creep).
Summary of Fixes and Precautions:
Push filament down before pulling it out.
Don’t keep material heated for long periods of time without printing.
Make sure the barrel cooling fan is working and that all the blades
are intact.
Confirm wiring from the board to the barrel cooling fan is connected
properly.
Clean your barrel cooling fan and remove all dust.
Make sure your hotend has a heatbreak.
Check your settings that you are using the proper extrusion
temperature for the material you are printing.
In a well-ventilated area, torch metal parts when required.
Make sure your thermistor is reading the correct temperature.
Adjust the idler tension.
Tweak the print speed.
Confirm you understand what is said in the “Settings Issues”,
“Hotend Can’t Reach or Maintain Temperature”, and “Hotend Not
Reading Correct Temperature” chapters.
Read the “Stripped Filament” chapter if experiencing this issue
frequently.
It is smart to have replacement heater blocks, heaters, and
thermistors so you do not need to wait for delivery to fix your
machine when required.
Over/Under Extrusion
Over and under extrusion is normally caused when your stepper motor is
not turning the proper amount of steps, and results in either too much, or too
little plastic being extruded. This will lead to ugly and/or brittle parts.
Keep in mind that a minor amount of under or over extrusion can be
unnoticeable to the human eye, so it is smart to check this intermittently
regardless if you are experiencing issues (as mentioned in the “Mandatory
Maintenance” chapter). Unnoticed under or over extrusion can cause issue
with parts that need to fit together or are used under significant loads.
NOTE: For most of your issues, you will want to skip down to the
Check and Fix your E-steps section of this chapter.
Confirm the proper filament diameter is
set
This sounds silly – but it has happened to me. Without thinking, I have had
my filament diameter set to 2.85mm on Cura, but I was actually using
1.75mm. This will 100% result in a print that looks far under extruded.
The opposite is true if you are using 2.85mm filament but have your slicer
set to 1.75mm – your part will look massively over extruded.
Check this before doing any further solution explained, since you will just
be wasting your time. This is an easy fix – just make sure you have this set
correctly in your slicing software.
Over Extrusion
Drastically over extruded parts will be fairly easy to tell either to the naked
eye, or easy to tell because parts are not fitting together. If you factored in
your machine tolerances (which I go over in the “Parts not to Proper
Dimensions or Not Mating Together” chapter) and parts are still not mating
together, you likely are experiencing a bit of over extrusion.
Check to see if nozzle is degraded
Nozzles can become degraded over time from material constantly running
through them, as well as from times you started a print too close to the build
plate. Some materials, such as the Carbon Fiber Reinforced blends, require
a hardened steel nozzle to prevent rapid degradation.
When your nozzle degrades, the diameter will get slightly larger than it was
when factory shipped to you. This can lead to some parts of your print
looking as though there was over extrusion (or may just look generally
ugly). You won’t really be able to tell if you have this issue, unless your
nozzle looks like the one on the left below. The nozzle on the right has been
used, but it clearly has not been as degraded as the one on the left. Worn out
nozzles will lead to ugly prints far before they get as bad as the one pictured
below:

Normally a
nozzle won’t be this noticeably degraded, so you will want to keep track of
how much printing you are doing on a machine. If you have gone 6 months
of daily printing on a brass nozzle, it is definitely time for a replacement. It
is smart to always keep 1-2 spares on hand to test if this solves your issues
of over extrusion.

Above the two

parts have the exact same G-code, but the one on the right is with a new
nozzle. The part on the left was printed with a hardened steel nozzle, so
even these wear out after hundreds of hours of printing with abrasive
materials. While the print on the right is not perfect, you can see just how
much a nozzle with the proper tolerances will help to achieve clean prints.
Before replacing your nozzle though, you should check your E-steps, as
explained further in this chapter. It is also well worth the investment to get a
hardened steel nozzle so you do not have to worry about this issue for a
long time. I personally have not used one due to the price, but you can even
go with a ruby tipped nozzle to never have to worry about this issue again
(they cost roughly $100 though). I have standardized to using the NozzleX
by E3D.
Under Extrusion
Unless extreme, under extrusion is much more difficult to diagnose with the
naked eye. This is because parts will bridge gaps just fine, the surface
quality will look good, and parts will mate together with ease. The biggest
issue comes with the integrity of your parts. They will delaminate easier
and will break under far less pressure than the part should be able to handle.
Check tension on extruder idler
Make sure there is enough tension on your filament by the idler that pinches
the filament to your hobbed bolt/gear. When this idler is too loose, you may
experience less filament feeding through the hotend than there should be.
Too tight and you will experience further skipped steps in your extruder
motor, or even stripped filament.
Are you experiencing extruder motor
skips?
If you notice that your extruder is making a “clicking” noise, then the
stepper is skipping. Please refer to the “Extruder Stepper Skipping” chapter
to fix this issue – since an extruder that skips will cause under extrusion.
Not enough torque to extruder for nozzle
diameter
When using a direct drive non-geared extruder on a 0.25mm diameter
nozzle, I was experiencing what looked like massive under extrusion. I
checked my E-steps and tweaked my slicer settings multiple times but could
not fix the problem. What was occurring was minor skips in the extruder
motor, and minor grinding of the filament.

As explained in
the “Extruder Motor Skipping” chapter, I did not hear the normal clicking
noise you hear from extruder motors skipping, but I was essentially
experiencing the same issue. This is because a non-geared extruder does not
have enough torque to push through such a small nozzle.
You will even see on E3D’s website that they say a geared extruder is
required to print using their extremely fine diameter nozzles. After
upgrading to a Greg’s Wade setup, I was able to print through a 0.25mm
and 0.15mm nozzle without this under extrusion issue, and then after
upgrading further to a Bondtech BMG, I never experienced the issue again.
Reduce retraction and/or coasting
Having retraction set too low will result in stringy prints, but too high and
you may experience under extrusion.
Lubricate filament for all metal hotends
This one is a bit odd and new to me, but I have learned that the one issue
with all metal hotends is the fact that PLA is starch based filament, meaning
it will stick to the steel heat breaks when hot. This can add to friction and
potential under extrusion.
It would be smart to add a bit of lubrication for your filament if you are
experiencing hard to diagnose clogs on an all metal hotend. To do this
would just involve adding a small sponge to where your filament runs
through before going into your hotend. You would then add a drop or two of
Canola oil, or another similar oil.
This oil will then slightly rub onto the filament as it feeds into your hotend,
lubricating the heat break. The heat break will eventually get seasoned like
a cast iron skillet and not require further lubrication.
If you do not lubricate, you can have more frequent clogs, or just under
extruded parts.
Confirm you aren’t set to “Volumetric
Extrusion”
Another way that you can be under extruding can be if you have
“volumetric extrusion” turned on in your firmware. This can accidentally be
turned on if you scroll through your LCD screen as well, or it may have just
been turned on for a reason you weren’t aware of. Volumetric extrusion will
make it so you vastly under extrude if you didn’t set your slicer up to be
volumetric extrusion as well.
You can turn this off in Marlin, but an easy G-code command is “M200
D0”. Just make sure to type “M500” after to save.
Check and Fix your E-steps
For most under and over extrusion issues, you will want to check and
calibrate your E-steps. To do this is actually quite simple.
You will want to start off by measuring out 100mm of filament. You can
actually measure out even more for a more precise readout – you will just
have to account for that in the calculations below. I prefer to use White PLA
because it is the easiest to write on, has a low printing temperature, and is
cheapest - though you could use any material you have at your disposal (my
example below is actually with purple AIO Robotics PLA).

You can do this

in whatever method is easiest for you. I found it easiest to measure this
100mm when the filament is already fed into the extruder. You can also do
this on a desk before feeding, but 3.00mm filament, and 1.75 near the end
of its spool, are quite hard to keep from rolling back up.
Be as precise as you can by using a fine tip sharpie and holding the material
as straight as possible. Use calipers if you have them at your disposal. After
heating your hotend, you then want to push the filament down until the
lowest dot you made lines up with the top of your extruder, or somewhere
else you can easily line up the starting point (because you will need to
compare it to where it finishes).
The next thing you will want to do is to tell your printer to extrude 100mm.
This is done with a simple G-code command in your terminal.
If you normally print via SD card you will need to hook up to a computer
for this. If you print via Octoprint or a similar online program, you can send
the G-code commands from their terminals.
When hooked up to Repetier Host, or whatever program you use to control
your machine, and your hotend hot, you will want to give your machine the
command:
G92 E0
This sets your extruder to 0. Next you will want to give either the
command:
For 3.00mm Filament: G1 E100 F30
or
For 1.75mm Filament: G1 E100 F60
This will tell your extruder to feed 100mm, and is why it was important you
lined up your starting dot with either the top of your extruder or something
else that is easy for you to compare to.
Once your extruder has finished you will want to mark your filament at the
same spot you lined up your original dot (top of extruder in my examples).
If your 100mm dot lines up perfectly, then your E-steps are right on - but
even 1mm means that your printer is extruding incorrectly by 1%.
After marking where 100mm actually was, you will want to compare it to
where you measured 100mm to be at the beginning of this process. If higher
on the filament, your printer is over extruding, if lower on the filament,
your printer is under extruding.
After measuring this difference you will want to write down somewhere
how much your extruder actually fed. If your printer over extruded by
2.1mm, you will want to mark down 102.1mm. If it under extruded by
2.1mm, you will want to mark down 97.9mm. You will need this number
later on.
The next step in this process is to determine what your current E-steps are.
You can do this by either checking the firmware for your machine, by going
into the “Motion” section of your EEPROM (LCD Screen), or just by
giving it the command “M503” in your printer terminal. Direct drive non-
geared extruders have E-steps of around 90, while Greg’s wade and other
geared extruders have E-steps of 500 or more. If you have an extruder from
a popular manufacturer, they will list what their standard starting point for
E-steps should be (such as 420 being the starting point for the Titan
extruder).
If you are checking in the firmware that you use to flash your machine, you
will want to open it up. While in Marlin you will go to the
“Configuration.h” tab and scroll all the way down to where it says
“DEFAULT_AXIS_STEPS_PER_UNIT”, with E-steps being the 4th and
final number (if using one extruder). The X, Y, and Z steps should never be
changed and are a calculation based off of the parts you are using. This is
only if you plan on working in Marlin, rather than using your printer
terminal.

You could also

type M503 into your terminal to be given a readout of what your current E-
steps are. You then take this number and multiply it by 100 (the amount you
were attempting to extrude). You will then divide this new number by the
number you wrote down earlier.
If you decided to check your E-steps by feeding out more than 100, you
would multiply by that number. I actually will often feed out 200mm
instead, in order to get back a more accurate number. Just remember to
change the calculations accordingly.
For example, if your current E-steps are 90.5 as shown above, you will
multiply it by 100 to get 9050. We will then divide 9050 by how much you
extruded earlier. So if you extruded 102.1mm, you will take 9050 and
divide it by 102.1 to get 88.64.
90.5 x 100 = 9050
9050 / 102.1 = 88.64
88.64 in this above example would be your new E-steps. As you can tell it
is lower than it was before, because in this example you were correcting for
over extrusion.
You will now set your E-steps. You can do this through your terminal,
EEPROM, or by flashing your firmware. If you are going to do this through
your terminal you will want to give the M92 command, by typing M92
E88.64. You will then want to type M500 in order to save these settings.
Without typing M500, the number will be reset when turning off your
machine.
While you can set this number on many LCD screens under the “Motion”
section, it will only save permanently if you have the option to save your
settings after doing so, just as with typing M500 in the example above.
Otherwise your E-steps will reset once you turn your machine off.
You can then of course change it in the firmware by changing the E-steps
number, and flashing your machine.
Thomas Sanladerer has a great older tutorial video going over all of this on
his channel which you can find by searching “calibrating your extruder” on
YouTube. Thomas really knows his stuff and I suggest to everyone that they
follow what he does. He has personally taught me many of the things I now
know about 3D printing.
Flash your firmware
Finally, you can reflash your firmware with your new E-steps. As
mentioned in the “Tips if Still Not Working” chapter, you will want to
reflash your firmware regardless periodically if experiencing non-stop
issues. This is something I do not need to do quite as frequently as I have in
the past, but it definitely does not hurt.
You will do this by downloading the proper firmware for your machine if
you haven’t already. You can normally find this firmware by searching for
your machine online, but you likely already have it from when you first set
up your printer.
Some printers, such as the CR-10 series, do not come with the ability to
flash your firmware via Marlin. If you would like to do this on such a
machine, you will want to bootload via an Arduino Uno. TH3D Studios has
a great tutorial on this and ability to purchase all parts required
(TH3DStudio.com). If you have a machine such as this, you can still change
your E-steps via a terminal, or as a last case scenario, edit the “flow %”
settings on Cura, as explained in the section below.
Double click the Arduino file to open up Marlin. If you are not changing
your E-steps, you can just proceed below to the next paragraph. If you are
changing your E-Steps, go to the “Configuration.h” tab and scroll down to
where it says “DEFAULT_AXIS_STEPS_PER_UNIT” as explained earlier.
You will then change the fourth number to your newly determined E-steps.
Some firmware are a bit different than what I am showing, so be sure to do
some research on your particular firmware.
Flashing your firmware is quite simple after this. Hook up your printer to
your computer and then choose the proper port in Marlin by clicking
“Tools”, scrolling over “Port” and choosing the port to which your machine
is hooked up, normally the highest number.
You will then choose the board you are using. If you are using a RAMPS
board, you will choose “Arduino/Genuino Mega or Mega 2560”. If not –
you will need to check with what board you are using and what the
manufacturer says. Once ready, you will want to click on the arrow
“upload” button:
 The code will
then compile and upload to your machine. If you experience errors while
compiling, read the specific error you are fed out. If could be something
very simple to understand and fix, or it could be something much more
complex.
If confused, copy and paste the error message that is read out to you into a
Google search. There is likely someone who has experienced and fixed the
same problem. This is exactly how I fixed my issues with compiling when I
was fed out an error that did not make sense to me.
Assuming you have the proper firmware for your machine, you shouldn’t
have these issues.
Please keep in mind I have had to restart my computer a few times in the
past when the file would just not upload. It may be worth restarting yours if
you are experiencing an issue you are unable to diagnose.
Many people now prefer TH3D’s firmware since it is so user friendly to
setup rather than standard Marlin.
You can also reset your printer to factory settings, which is similar to
flashing it, by giving the command “M502”. Remember that this will reset
your numbers, so if you need to change your E-steps, you will then need to
give a new M92 command with M500 saving the settings.
Changing Flow % in slicing software
If you have a machine that will not allow you to use Marlin and cannot save
the settings using the M500 command, you could literally just change the
Flow % in Cura.
This is not ideal, but can get the job done if needed. Essentially, you will
not need to know any E-steps, you will just need to know the percentage
that you over or under extruded in your test you performed earlier. If your
extruder fed out 102.1mm, then you would divide 100 by 102.1 to be read
out .9794. You can then set your flow percentage to 97.94%.
 Summary
of Fixes and Precautions
Step one should be to see if you have your slicer set to the correct
filament diameter.
Step two is to check your E-steps.
Read the guide above on checking your E-steps or watch Thomas
Sanladerer’s YouTube video on “Calibrating your extruder”.
Correct your E-steps via your terminal, EEPROM, or by re-flashing
your firmware.
If you cannot change your E-steps via one of the three methods
above, you can also change your flow %.
Replace nozzle if degraded or if you have done countless prints on a
standard brass nozzle.
Check the tension on extruder idler.
If under extruding on an all metal hotend, try lubricating the
filament.
Confirm you are giving enough torque for the nozzle diameter you
are using.
Understand the possibility that your hotend is not reading the proper
temperature as mentioned in that corresponding chapter.
Parts Being Knocked Over
Your part being knocked off the build plate can happen quite frequently,
especially when dealing with tall, skinny prints on Cartesian machines.
Proper bed adhesion
Goal number 1 when it comes to having parts not being knocked over is
having the proper bed adhesion. This includes knowing the right mixture or
bed sheet for the material you are using, the correct bed temperature and
brim/raft application, as well as having the proper z-height with a level
build plate.
To review this further, make sure you check the “Bed Adhesion”,
“Unlevelled Build Plate”, and “Z-Height” chapters. If any part of your print
is too far from the build plate, you will be very susceptible to your part
being knocked over.
Adding a Z-hop

As mentioned
elsewhere in the book, a Z-hop refers to the printer head moving up while
travelling. The printer head (or build plate when working with a CoreXY
machine) will have the nozzle move away from the print by the determined
amount in your slicer settings. This will mean that the nozzle will not be
running into your print when travelling, reducing the odds of it being
knocked over.
I always have my Z-hop height set to the layer height of my print. As you
can see from the photo, it is currently set to 0.2mm on this profile, meaning
my layer height for this print is 0.2mm. I have just found this to work best,
because if you have a Z-hop set lower than the layer height, you run the risk
of still bumping into the top of your print. I increase the Z-hop larger than
my layer height when printing at large layer heights (over 0.4mm).
Avoid parts when traveling
As you can see in the photo above, I also have both the avoid supports and
avoid printed parts when travelling checked. This is a fairly new feature
offered in Cura, in which the path of your printer head will avoid both
printed parts and supports while moving. This can increase print time, but I
find it best to use to avoid any parts being knocked over.
To be honest – I am not quite sure if both Z-hop and this feature are
required, or if one cancels out the need for the other. I figure I have had so
many parts get knocked over in the past that it would just be best to take all
precautions to prevent this, but you can play around at your own discretion.
Turn combing off
When combing is on, you get the option to avoid printed parts when
traveling. This isn’t always the best option though, since it will depend on
just how large your layer heights are. It seems that when I use large layer
heights, even with avoid printed parts when travelling checked, my nozzle
will still run into the infill. For this you will want to turn combing off. It
may add to your retraction headaches, but the printer will always perform a
z-hop when travelling and will avoid your printed part.
I have combing on for any print that is 0.3mm layer heights or lower, but
anything higher I will have it turned off.
When combing is off and you are printing with large layer lines, it should
also be accompanied with an infill pattern that only goes in one direction
per layer (such as “lines). That is something I learned when printing with
the E3D SuperVolcano at 1mm layer heights.
Working with very thin tall prints
This is also covered in the “Z-Wobble” chapter, but essentially a very tall
skinny part is far more likely to wobble and get knocked over during a long
print. This should not be an issue on CoreXY machines where the build
plate only moves downward, but on Cartesian machines where the build
plate rattles back and forth, the very top of a tall skinny print will start to
sway back and forth.
This swaying will not only cause ugly Z-wobble prints, but it can cause a
print to be knocked over. This is because the nozzle may try and start the
print slightly to the side of where the top of the print swayed to. Get this
happening a couple of times and this part will easily fall over.
This is especially noticeable when working with some support material.
Often a part will require a very tall support structure, but may not need to
cover a large surface area. These thin towers can fall over before they get to
where you need them to be.
Unfortunately, when working with a Cartesian machine, there isn’t much
that can be done to prevent this. Of course you need to have a proper brim
for great bed adhesion, but if a part is extremely thin and tall, there will be
swaying. There are essentially two things you can do in this scenario – cut
the part into two sections or add further scaffolding to help anchor.
There have been some thin parts I have printed in the past that I was just
forced to slice in half and glue together post printing. This is clearly not
ideal for mechanical parts, but anything this thin will be flimsy regardless.
You can also add manual support structures to the model, anchoring the part
to the build plate every so often, to make sure no swaying occurs. If you are
just building a thin tower, you will need support structures attaching to the
side. This can be done in programs such as Cura.
Anchoring Prints
I am sure there are better ways to do this, but the easiest way I know of
would be to anchor your print in Cura. I have rarely done this, but it
definitely helps with a tall, skinny print wobbling back and forth. This is
also explained in the “Z-Wobble” chapter.
Below is an example of two skinny swords from a Deadpool print that I
made for my YouTube channel. When not adding any anchors, my
Cartesian machine would wobble the build plate back and forth and cause
the top half of these swords to look extremely ugly (if they didn’t just get
knocked off).
Cura now allows you to bring in a second model that intersects with your
main print. They also allow you to print a part entirely as support. This
means you can drag in a second object that acts only as support for your
main structure.

This rectangle in
the example above is thin, so that it won’t take up too much material, yet
will extend the anchoring for the sword (I added a second sword to compare
how it will slice). After bringing in a shape that will work for your model,
you can choose the model and click “Print as support”.
 After turning the
shape into “Print as support”, you can then drag it over your tall, skinny
print.

As you can see in

“Layer Mode”, this entire shape is now support structure that can help to
anchor your tall skinny print to help prevent this wobbling back and forth.
As mentioned – there are many other ways to do this, this is just the
simplest way I know of since it allows you to do this right in your slicing
software.
This process is explained in detail as well on my video titled “Combining
Parts on Cura” if you would like to see it in action.
Summary of Fixes and Precautions
Ensure you have the proper bed adhesion – including having a level
build plate with the proper starting Z-height.
Add a Z-hop (normally the same distance as your layer heights).
Utilize the ability to avoid parts and support when printing in Cura’s
slicing software.
Turn off combing and use “lines” as pattern infill when printing with
very large layer heights.
Plan ahead when working with a tall and skinny print. You may need
to cut the part in half or add anchoring to make sure the part doesn’t
wobble back and forth.
Parts Not Mating Together
This issue can be as minor as when you print two parts that are meant to fit
together and they don’t without some sanding, to as far as one or multiple
axis’s being off by over 100% in scaling.

You will have to

diagnose how bad this problem is. If it is minor, proceed with the next
couple of steps.
Confirm you factored in the appropriate
tolerances
There are clearly tolerances involved with 3D printing, and they can vary
drastically on the nozzle diameter and layer heights of your particular print.
While there may be sources that say the tolerances are tighter than the
numbers I am saying, these are what I use and what has worked for me
throughout all of my prints.
The tolerance of the print that I will use is the layer heights you are using in
the Z-direction, and roughly half the diameter of your nozzle in the X/Y
direction. So, as an example, if you were printing 0.1mm layer heights on a
0.4mm nozzle, your tolerances will be roughly 0.1mm in the Z-direction
and 0.2mm in the XY direction.

While that is a
general rule of thumb, you may actually be able to achieve tolerances
tighter than this on your particular machine depending on how everything is
set up. You should find out your exact tolerances by printing a tolerance test
– like the one below designed by A_Str8 on Thingiverse (though there are
many out there that should accomplish the same idea).

Since 3D printing is additive, it will almost always err on the side of adding
more material than less material. This means that parts will be slightly
larger and holes will be slightly tighter.
So, if you were to design two parts that mate perfectly together without any
clearance, no matter how good your settings are, you will likely not be able
to fit the printed pieces together without a lot of sanding.
I always suggest parts that need to be perfect to their dimensions, or ones
that need to mate together, have the size of their holes increased, and the
overall size of the part decreased. The amount you should factor in should
be based off of the tolerance test I suggest you print a couple paragraphs
earlier.
For instance, using the same example as above, if you are printing at 0.1mm
layer heights on a 0.4mm nozzle, you will want to increase the diameter of
holes being printed in the XY direction by 0.2mm, and decrease the size of
the part in the XY direction by 0.2mm (and 0.1mm in the Z direction).
With this tolerance, parts will mate tightly together. If you would like the fit
to be a little loose, you will want to increase this to 0.3mm in the above
example.
Based off of the photo I show above, I am able to achieve tolerances of
0.25mm for a really tight fit, but 0.35mm for a looser fit. So you need to
factor in the corresponding clearances in your part depending if you want a
tight or loose fit.
This is another reason printing in a high resolution on a fine nozzle is
beneficial for printing a part with accurate dimensions, but will of course
result in a much longer print.
Replace your nozzle
Your nozzle will be degraded over time, especially when using one made of
brass. Abrasive materials at hot temperatures will slowly make the diameter
larger than what you think it is.

The example
above is an extreme version of what I am talking about. The nozzle on the
left had been worn out from being used when too close to the print bed, and
from being used for a couple of months (not from my machine). Not only is
the tip extremely worn down, the hole itself is clearly larger and not as
precise.
You can see some example prints and more explanation in my YouTube
video, “The Importance of Replacing Nozzles”.
While you are trying to lay down 0.4mm layer lines, your nozzle may
actually be closer to 0.6mm in diameter, and not be a perfect circle. This
can lead to ugly parts, and can definitely lead to your parts not mating
together. If you are using a brass nozzle, make sure you replace it every
couple hundred hours of printing. I definitely suggest upgrading to a
hardened steel nozzle so this does not become an issue nearly as quickly.
Check to see if you are over extruding
You will definitely want to visit the “Over and Under Extrusion” chapter in
this book if you factored in tolerances but parts are still coming out slightly
too large.
Be sure you are as accurate as possible when checking your E-Steps
because even a slight over extrusion can cause problems when you are
trying to print two parts that are meant fit together accurately.
Many people suggest setting your e-steps to 98% of the number you are fed
out, since a very minor amount of under extrusion should help with mating
parts together.
Make sure your material hasn’t absorbed
moisture
Materials left out not vacuum sealed or with a dehumidifier will
undoubtedly absorb moisture. When this occurs, you will experience a
myriad of printing issues, one of which being having trouble mating parts
together.
You can read more about this issue in the “Stripped Filament” chapter.
Tighten belts
As mentioned elsewhere in this book, it is possible to over tighten your
belts, but you will really have to be trying to do that. If you are
experiencing parts that are not to the correct dimensions, your belts may be
too loose.
You do not want a lot of slack in your belts because not only will quality of
your parts decrease, you can experience actual dimensional issues. This
happened slowly over time on just about every machine I have used. A part
printed on one machine over time would not mate with a part printed on
another.
It turned out that tightening the belts fixed the issue immediately. This is
another reason having a way to easily tighten your belts will be extremely
useful and necessary for practical preventative maintenance.
Confirm stepper pulley has proper
amount of teeth
This is a strange one and should only occur if you recently changed the
pulley attached to your stepper motor. This happened to me once, and it
took me about 3 prints of confusion to realize what was going on.
If your stepper pulley has the incorrect amount of teeth for your machine,
your scaling for that dimension will be very far off. From what I can tell,
the vast majority of FDM machines use 20 teeth pulleys for their stepper
motors.
Read the “Settings Issues” chapter
If you have confirmed everything above, and parts are not mating together,
make sure you read the “Settings Issues” chapter. You would be amazed just
how much tweaking your settings can affect the quality of your print. Along
with making sure you don’t have your flow rate over 100%, minor
fluctuations in temperature for specific materials can affect the viscosity
which can cause a print to ooze more than it should. This will result in a
part that is not to the proper dimensions.
Print a large calibration cube and check
XYZ steps/mm
This really should not be needed if everything is built properly and you are
using the correct firmware for your machine - but it may be smart to do on
very large machines that you built yourself.

Find a calibration cube on Thingiverse, or create your own that is large and
uses the least amount of filament as possible. This can be a hollowed out
cube that is only shells and has not top or bottom, or whatever you can think
of that has specific dimensions of at least 100mm. If you have the filament,
space, and time, you should go even larger.
This is because the tolerances involved with your machine will effect these
numbers the smaller the part you print. This process would then be the same
as when you checked your e-steps.
I cannot stress enough how important it is to check your e-steps and to
check everything else described above before printing your calibration part.
There is no point changing the X, Y, or Z steps/mm if a belt is loose or if
you are over extruding. Your X, Y, and Z-steps should be a calculation
based off of the parts you are using – and there is no reason to tweak this
UNLESS you built the machine yourself and you were wrong with your
calculations in flashing firmware.
Find your X, Y and Z steps per mm in your firmware – they are located
directly to the left of the E-Steps/mm (as explained in the “Over and Under
Extrusion” chapter). Take that number and multiply it by the number of mm
your calibration print should be in that dimension (if printing a 100mm
cube, multiply by 100). Pull out your calipers and measure your print in that
direction for what it actually printed.
Make sure you do not scrape off your print before marking or remembering
which direction is which. Divide that newly found number by the actual
number read out by the calipers. This is your new steps per mm for that
dimension.
As mentioned, if you have a printer that is using the proper firmware and
parts, with settings that are correct for the material you are using, this
should generally not be needed. I never will do this on my machines
because everything is just based off of calculations.
Summary of Fixes and Precautions
Make sure you factored in clearances for parts that need to be mated
together or precise. These tolerances have to do with your layer
heights and nozzle diameter.
Print a tolerance test to know what your clearances should be.
Replace any worn out nozzle.
Make sure you are not over extruding by checking the e-steps.
Tighten all loose belts.
For parts that are far off in their accuracy, confirm you have the
proper amount of teeth for your stepper motor pulley for your
machine/firmware.
Read the “Settings Issues” chapter since many issues in minor
dimensional accuracy have to do with having the proper settings for
the material you are using.
For large machines, or machines you do not have the firmware for,
you may want to check the X, Y and Z steps/mm by printing a very
large calibration cube. Only do so after confirming all of the above.
Poor Layer Adhesion
Having strong layer adhesion is not only mandatory for watertight parts, but
it is needed for clean, strong prints. If your individual layers do not stick
together well, you are bound for a part that will break and peel apart.
Understand the material being used
Each material requires its own settings, including temperatures and speed.
You need to make sure that you are using the proper settings for the type of
material you are using.
Carbon fiber reinforced blends are more likely to have poor layer adhesion
due to their properties. Polymaker is currently working on carbon fiber
reinforced blends that increase this layer adhesion, but it is going to be a
problem with most of these types of materials.
Refer to the “Materials Science”, as well as the manufacturers print settings,
before moving forward in trying to fix this problem.
Increase the extrusion temperature
One of the most common reasons this happens is because you are printing
at too low of an extrusion temperature.
Following the manufacturer guidelines is normally a surefire way to prevent
this, but a few times I have had to go above these recommended settings to
make sure I had a strong enough layer adhesion.
The photo above was a failed print I had when printing in NylonX by
MatterHackers. They recommend 250 – 265 degrees Celsius for printing, so
I went ahead and tried 250 degrees. I was left with the part you see above,
something with far too weak of layer adhesion. After upping this to 265
degrees the part printed just fine.
This problem was also increased because NylonX is a carbon fiber
reinforced nylon, and as mentioned earlier in this chapter, carbon fiber
reinforced materials are more likely to experience poor layer adhesion.
Try slightly increasing your extrusion temperature to see if it helps with this
problem.
Under extrusion
Another reason for poor layer adhesion is under extrusion itself. If your
extruder is depositing less filament than it thinks it is, you are bound to
have weak layer adhesion.
Confirm you have the proper E-Steps set by referring to the “Over and
Under Extrusion” chapter in this book.
Not enough torque
As with the “Extruder Stepper Skipping” chapter, you could be working
with a stepper motor/extruder setup that does not have enough torque. If
your extruder motor skips, you will essentially be left with an under
extruder or poor layer adhesion print.
The best way to remedy this is to upgrade to a geared extruder, if you
haven’t already. You can do this via printing a Greg’s Wade extruder or by
purchasing one. The two that I use are the Titan extruder by E3D, and my
current favorite is the Bondtech BMG dual drive extruder.
Turn off active cooling fan
While having your active cooling fan turned on will benefit the majority of
prints and materials with their surface quality, many filaments require you
keep this active cooling fan off for proper strength and layer adhesion.
Another reason the print from the photo in the beginning of this chapter
failed was that I kept my active cooling fan on. It seems that MatterHackers
states their NylonX should be printed without any active cooling fan.
This not only helps to prevent warping, but will also help to achieve strong
layer adhesion. Generally, the higher the heat capacity and density of the
polymer, the more beneficial a cooling fan will be. For lower density
polymers such as ABS, HIPS, etc. that are below 1.2g/cc, the fan is
typically recommended to be turned off.
Make sure material is stored properly
As with many other problems, make sure your material is stored properly.
Old, wet material, or poorly made, off-tolerance filament can lead to issues
that are very difficult to diagnose. If you consistently get poor layer
adhesion from one spool regardless of what you do, try using a different
spool. If the issue does not continue, it is likely problems with that
particular material.
Delamination

I personally consider delamination a different problem than just poor layer

adhesion. You can have extremely strong layer adhesion but still experience
delamination when working with high warping parts.
Because of this – I cover this specific issue in the “Warping” chapter, since
delamination is far more a symptom of high warping materials rather than
poor layer adhesion.
Summary of Fixes and Precautions
Read the “Material Sciences” chapter.
Check the manufacturer recommended print settings. Do not go
faster or change the temperature outside their ranges to start your
tests.
Switch from using a carbon fiber reinforced material if continually
experiencing issues, since carbon fiber reinforced materials are
going to have more issues with layer adhesion than other types of
filaments.
If experiencing poor layer adhesion while staying within the
recommended settings, try increasing the extrusion temperature
slightly.
Confirm you have enough torque and that your extruder motor is not
skipping.
Turn off active cooling fan if the particular material does not call for
it.
Make sure there is no issues with the material you are using.
If experiencing delamination – check the “Warping” chapter.
Post-Processing
This is not going to be classified as a failure, but rather tips to help you
combine smooth, sand, and paint your 3D printed object. There will be no
tips on how to print your part in this section, just how to post-process it.
I have had a decent amount of experience with post-processing, and will let
you all know my results below.
Loctite Super Glue Gel
Combining 3D printed parts can be a difficult task, which is why Loctite
Super Glue Gel has become the preferred favorite of many 3D printing
enthusiasts. This stuff is quite strong and can dry in under a minute. When
you have a part that can’t easily be clamped together for drying, or a small
part that can easily break, you will likely want to go with using Loctite.
Remember that this stuff dries fast so you can accidentally glue your finger
to the part if you are not careful.
After you have used everything you can get out, make sure you remove the
tube from the hard plastic bottle. There is still about 30% of the glue in
there that you can’t get out until removed from the casing.
This works great on PLA and ABS, as well as many other plastics, but it
doesn’t work great on everything. Nylon materials are very hard to find the
correct adhesive.
Devcon Plastic Welder
This is a two part welder that you mix together and apply for parts you want
to have a very strong hold. Devcon is just one manufacturer of Plastic
Welders, I haven’t tried them all. This is my go-to for any part I want to be
as strong as possible. In fact, I have found that Devcon Plastic Welder is
stronger than the actual layer adhesion, since on all of my tests the part
would break before the bond did. The issue comes with the fact that it takes
about 10 minutes to get a decent hold, and close to 24 hours before you get
a fully cured weld.
Because of this, I use Loctite Super Glue Gel for those hard to hold and
small spots, and Devcon Plastic Welder for just about everything else.
The only issue I have found is that every so often I get a bottle where one
part will come out at a different flow rate than the other. This has led me to
wasting a decent amount of the product. I believe this is due to me being
shipped old product, but it is hard to say exactly why.
Notes about Super Glue and Plastic
Welding
These two products work great with PLA and many other hard plastics, but
they do NOT work well with Nylons. I have only done a minimal amount of
testing on bonding nylon parts together and I have yet to find something
that I find acceptable. If you are designing a cosplay or fan art piece, use
PLA or other hard plastics. If you are designing a mechanical piece to be
printed in two parts in nylon, you should design those two parts screw or
clamp together. Do not trust a super glue or plastic welding hold for parts
that will be used in mechanical applications.
Starbond Adhesives
Starbond has a wide variety of options and have recently sent me samples to
test out. I will have a video out (hopefully by the time this book is released)
that will go over testing different adhesive products and how they work
with different types of materials. Please refer to my YouTube channel by the
time of purchasing this book to find out those results.
My minimal testing with Starbond so far has me very happy. They seem to
work amazingly well and come in thin, medium, and thick viscosities. The
thin is similar to water, and can get into any crevice you need. The thick is
similar to the Loctite Super Glue Gel. They also offer an accelerator spray
that can make it so you only have to hold parts together for about 10
seconds.
So far – I definitely recommend you checking them out.
Sanding
Sanding is key regardless of the methods you choose to go with below, and
will help you to clean up any print. For the majority of materials (including
PLA) I start with 220 grit sandpaper. This is just about the right roughness
to help smooth your print out without deforming the look. You can go
slightly lower than this for very hard plastics, just be careful.
From 220 you can move to 800 and even 2000 grit sandpaper. If you start
with these high grit sandpapers, you won’t get much progress, so it is smart
to start with 220 and work your way up. You will likely want to wet the
sandpaper as well since it helps in the process.
I use a circular power sander for many flat prints – especially those that I
combine two parts, but you need to be very careful to not keep the sander in
one spot for too long. This is because it will heat up your part past the glass
transition temperature (especially with PLA), and can deform your print.
Bondo
This stuff is very hard to sand without damaging your part, so make sure
you are only using it to seal large seams that need to be strong. I have used
this a few times in the past and you can really get a smooth seal, it just
comes with quite a lot of work.
When Bondo hardens it cannot be easily hand sanded. This means you will
want to have an electrical sander (or a Dremel sander for small areas). This
issue with this is that you will have to be very careful to not accidentally
damage the printed part. Not only can you accidentally dent the printed part,
sanding gets hot, so hot it can deform a PLA part.
But when it comes to having a strong seal where no one can see the seam,
you will want to use Bondo. Otherwise you might want to try out Spackle.
Spackle
This is really for display pieces only, since it can accidentally be dented or
scratched off with abrasion, even when fully dried. For very small seams, or
even small gaps in layers, I will rub on some spackle using my fingers. I am
able to get a very small amount of this stuff into areas, and then after a half
hour use some 800 grit sandpaper to clean it all up.
The problem with spackle is that even after it dries it won’t be that hard.
This means you can accidentally dig a finger nail into it. This is why this is
best for very small gaps on display pieces and should never be used on
anything that needs to be used mechanically.
Model Putty
Personally, I have yet to use model putty. I know I should, I just haven’t yet.
But from what I see from other makers, model putty can work as a great
alternative to both Bondo and Spackle.
Acetone vapor bath for ABS and carbon
fiber reinforced ABS parts
One of the best parts of printing in ABS is the ability to acetone vapor
finish your parts. PLA and other materials are not soluble in acetone,
making them unable to be post processed this way. Not only can it make a
print stronger and more water tight, it also gives a great finishing shine to
parts that resemble an injection mold quality. Prints are smoother to the
touch and overall easier to work with after acetone vapor finishing.
Please note that I have not actually done an acetone vapor in a couple of
years, so there are likely other methods out there.
Along with a high glass transition temperature, this is another reason you
would still use ABS in 3D printing today.
You do have to keep in mind though that this can definitely be overdone and
lead to a destroyed print, so use caution when proceeding with these steps.
***CAUTION*** Acetone is EXTREMELY flammable, and
this process should only be done in a well-ventilated area with
absolutely no open flames. If you are not sure of your setup,
DO NOT proceed.
Step 1: Prepare your slow cooker in such a way that you are using a metal
grate (often comes with the slow cooker). This metal grate needs to be
entirely taped off on the bottom with packaging tape and elevated slightly
off the surface of the cooker. Make sure to use clear packaging tape as ABS
parts will not stick to it unless overexposed to acetone vapor. This will help
prevent the acetone from bubbling up and accidentally directly splashing
your part during the heating stage.
Before turning anything on or putting in the metal grate with your part, be
sure to add a few tablespoons of acetone.
Step 2: Place your part on the newly taped off metal grate and put into your
slow cooker. You will then close your slow cooker and put it at the
LOWEST settings. This is a VERY fast process, so do not try this without
reading all of the steps and researching further.
Leave your part on the metal grate in the warm cooker for no more than 45
seconds. I had a method down where I would leave it on for 30 seconds, off
for 15, and then on for 10 final seconds. This process will vary with each
slow cooker you use.
I actually used to use a big broiler with a similar setup that I would put onto
a hot plate for larger ABS prints. This process requires roughly 10 minutes
though, due to the large volume of the broiler.
I recommend that you always error on the side of less time. You can always
do another round of acetone vapor if you determine that the print requires it.
Step 3: After your quick acetone vapor bath is complete, remove the grate
that is holding your part and put the two off to the side (onto a countertop
that you do not care about). After allowing for 30 minutes or more for
drying, you can remove the part to be vacuum purged.
This step is not needed but definitely helps with the strength of the part as
well as the time required to dry. Doing the process above without a vacuum
purge will require 24 – 48 hours before the part is to full strength.
Note: Now that I have parts which were acetone vapor finished over two
years ago, I am noticing some issues with this process. While those parts
looked great for a long time, they are now showing some cracks. I can’t
explain exactly why this happens, but feel it necessary to let you know that
it has happened to my acetone vapor prints.
XTC 3D for PLA and PETG
I like to be entirely honest with my reviews, and while other’s have seen
some amazing results from this stuff, I just personally have not. I am not
sure if I am doing something wrong with the mixing or what, but my results
are never quite what I see other’s getting.
The idea behind this is XTC is that it is a protective and smoothing coat for
finishing 3D parts that does not melt plastic. XTC-3D should fill in gaps
and retain a smooth, shiny finish.
I have definitely had some semi-successful results in the past, it just often
becomes more work than it is worth. First, you have to make sure the part is
sanded as best as you can with standard 220 grit sandpaper. You then need
to wear gloves and be in a well-ventilated area as you mix the two part
goop. You then paint on an even coat, wait for it to entirely dry, and give it a
further couple passes of sanding. After a decent amount of elbow grease,
you should be left with a very smooth outer surface.
With some practice I am sure this can be perfected, I just personally prefer
other methods at this point.
Polysher and PolySmooth
Polymaker has also made a product called the Polysher which works
exactly as an acetone vapor bath, but is made specifically for 3D prints
utilizing isopropyl alcohol. Rather than being soluble in acetone, their
proprietary PolySmooth filament is soluble in alcohol, making a vapor bath
work perfectly to remove layer lines.
I was given a Polysher for review a year or so ago (which is up on my
YouTube channel) and was very happy with the results. It is much safer
than going with an acetone vapor bath, but you are limited to only using
their PolySmooth material (or another alcohol soluble filament), and you
are also limited on size to their Polysher. This means this is far safer than
going the acetone vapor path.
This is great if you plan on doing a lot of display pieces such as miniatures
or action figures, since it works perfectly to result in an injection mold look
- but I would be cautious when working with mechanical parts due to the
lack of detailed information on PolySmooth, though I believe it to be a form
of PVB.
For further information, search for “Polysher by Polymaker Review” on
YouTube for my 3D Print General review.
I have actually found that after a lot of further testing you do not even really
need the Polysher to smooth out PolySmooth prints. If you have a spray
bottle, or preferably a spray mister, you can spray this alcohol directly onto
your print. You will instantly start to see the layer lines disappear.
This does make it so the underside of your print will stick and deform if you
are not extremely careful. You can do multiple passes of sprays to get even
smoother results, you just really need to wait a good 24 hours in-between
sprays, with a good fan focused on your part during that dry time. If you
have a way to heat the part up a bit and perform a vacuum purge, this time
will be decreased a lot.
What is pretty amazing is their PolySmooth clear material. With a few coats
of sprays, I am able to get this material just about entirely transparent. I
have never been able to get something quite as clear as this stuff. You can
see how it is done by watching my two videos on the topic called
“Transparent 3D Prints” and “More Transparent 3D Print Tests”.
Primer
If you plan on painting your part, you will want to spray a coat of flat grey
primer (or primer filler) before moving forward. Make sure you have
combined your parts, sanded them smooth, and cleaned them entirely off of
debris before going to this step. It would be smart to use a powerful air
blower if you have a compressor on hand as to make sure all dust is blown
off.
In a well-ventilated or outside area, with a tarp laid down, spray a light,
even coat of primer about 6 inches from your part. This will allow for
acrylics and other paints to stick to your part properly.
After waiting a couple of hours to fully dry, you can go ahead with spray
painting or hand painting. If you went ahead and used primer filler, you can
actually further sand smooth your print, which is why I prefer it over
standard primer. When I want a really smooth print I actually do a coat of
primer filler, wait to dry, sand, clean off, spray another coat of primer filler,
and then sand once more.
Painting
Over the past year I have done some testing with using an airbrush on 3D
prints, and have slowly gotten better at it. You can see my first attempts at
learning how to do this in the video titled “Learning to Airbrush 3D Prints”,
but many of my videos after this I use air brushing as well.
I have found it very difficult to paint within lines using an airbrush, but it
works amazingly to get an even spread of paint, as well as for shading. If I
want to cover an area in paint but want it as smooth as possible, I go with
airbrushing. If I want to get into shading, I also use airbrushing. You can see
how you can improve prints by watching the video titled “3D Printed Stan
Lee” on my YouTube channel, though I may have better examples by the
time you purchase this book.
If I need to paint within a small area, I will always go with hand painting.
Since I was hand painting my prints for a couple of years before purchasing
an airbrush kit, I have a bit more experience in this regard.
You can get a 24 color set of acrylic paints online for pretty cheap, it just
requires some practice to get details down. You can also use model paint, it
is just a tad more expensive. I have a few tutorial videos in this regard on
my YouTube channel if interested in learning further. Remember to always
allow time to dry and finish with either a clear satin or glossy spray coat to
make sure everything sets as it should.
I suggest getting a thin set of good paint brushes to make sure you can stay
within the lines. I always go with hand painting for features such as eyes
due to the fine detail required.
Keep in mind that not all materials are great to paint. I have attempted to
paint flexible filaments in the past, and it seems that acrylic paints will
crack when being flexed.
I have also learned how to paint eyes properly from a great tutorial video
titled “GalactiCustoms: 1/6 Paint Tutorial: Obi-Wan Kenobi- Pt 3 Eyes”.
The title is a bit long, but his description on how to paint eyes have
transformed the look of my painted parts.
Using shoe polish for shading
This is something I will often use watered down black acrylic for, but shoe
polish can also add a great shading effect to parts that call for it. You need
to make sure your part is as smooth as possible, the thicker the gaps in the
layer lines, the worse this effect will be. You also need to make sure the
previous painting is entirely dry with a clear coat on top, as to reduce any
chance of paint chipping.
Essentially, if you get some black shoe polish and spread it out on a paper
plate, you can then brush it onto your print with a paintbrush into the
crevices and indents that should show shading. This works great for detailed
figurines in which you want muscles or folds in shirts to show through
better.
The black shoe polish will naturally go into these indents, and all you have
left is to clean off the excess. Grab a sponge and get it wet. I used to suggest
doing this after the shoe polish had dried, but I have found it easier to just
wipe off sections as you go. Attempting to brush off dried shoe polish will
require enough pressure that you may chip off paint.
For a far more detailed explanation, you should check out Cosplay Chris on
YouTube, as he has perfected this approach with his “Custom Collectables”
playlist.
Print Pauses Mid-Print
This is when your printer thinks it is either still printing or the print is
complete, while in reality it looks as though the machine is frozen. This is
different than when you are “ghost printing” (Nozzle Clogs/Running Out of
Filament) because the printer never actually completes, or attempts to
complete, the full tool path it was given in the G-code.

This issue is not

very common but can be another one of those frustrating failures that can be
extremely difficult to properly diagnose.
Corrupted G-code
As mentioned in some other chapters, there is a possibility that your G-code
could be corrupted. I have had the experience of exporting a large G-code
and then preemptively dragging the incomplete file over to my printer/SD
card. You have to make sure to wait until the file is fully exported before
dragging to be printed on your machine.
Since I didn’t realize the G-code wasn’t done saving, the print stopped right
at the point I dragged it over. This caused the remainder of the tool path to
not be followed, and for the end G-code to never be triggered - meaning I
had a hot nozzle and build plate with a half-finished print paused just like
the photo you see above.
I had assumed that it was a connectivity issue, so I just reprinted, only to
experience the exact same issue at the exact same spot on the print. Re-
slicing and exporting the G-code fixed this on the third try.
You will notice some larger G-codes can take 5-10 minutes to slice, so you
do not want to get over zealous when trying to get your print started. An
easy way to tell if your machine was sliced at the incorrect time is to just
open the G-code in a notepad to see if the ending script is there.
Malfunctioning SD card
A malfunctioning SD card can lead to prints pausing mid-print. SD cards
should be formatted as FAT or FAT32, and the max size should be 32GB.
Try formatting your SD card, or just purchase a new one, if this is a
consistent issue.
Connectivity issues
If you are running your printer via a Raspberry Pi, this is something you
may experience. A connectivity issue could be a problem with your USB
cable accessing the internet, or with your Raspberry Pi itself (disconnects
from internet or local network do not cause failures, but you won’t be able
to reach the Octoprint UI from another device to do anything with the
printer if the pi disconnects from the network).
There is even the chance that your Raspberry Pi’s power cable has been
disconnected or bent to the point where it is not producing power. If your
Raspberry Pi loses power mid print, the print will just pause exactly where
it last left off.
I have experienced some very confusing situations in which I could not
properly diagnose why the connectivity problem occurred. I would start a
print overnight only to see it paused in place the next morning. A simple
reboot of the machine and of Octoprint would fix this just about every time.
A good precaution for this is to always make sure you are using the most up
to date raspberry pi and Octoprint firmware. Make sure you are using a
strong, USB, power cord, and Ethernet cable (if hardwired), and that they
have a good clasp (so that they stay in their ports).
I cannot stress enough how important it is to only use high quality USB
cables with ferrite cores (cylindrical objects on the cord near the
connectors) and make sure to have spares on hand. These cables degrade
and go out more often than you would expect. High quality cables can
typically be sourced locally for less than $10 and are well worth the extra
$1-$2 premium over generic lower quality cables.
Don’t use a phone charger, make sure you use a power adapter. Phone
chargers can scale down their output, so you want to make sure it is a full
power adapter. The red light on your Pi should always be on, it shouldn’t be
flickering.
If your pi is in a place where it can be rattled or moved repeatedly, you will
experience this issue more often.
This is also true if you were to remove an SD card mid print or were to
disconnect your printer from the computer when printing via Repetier.
Power malfunction
Power malfunctions can relate to either your power supply malfunctioning,
overloading a circuit breaker, or having an entire power outage - with an
outage being one of the hardest to diagnose if you didn’t see it happen live.
3D printers are energy hogs, especially when heating a large build platform.
You will not want more than two power hungry printers on one standard
circuit, otherwise you are prone to blowing it.
When I would run 12 printers simultaneously at SD3D, even though we had
upgraded our electrical, I would never start the bed heating process for
more than 3 machines at one time. That is because the initial amount of
power that is required is more than the energy required to maintain the
temperature.
Next, the power supply on your machine may actually be malfunctioning. If
you are running an inexpensive machine, you are likely running a very
inexpensive power supply. These blow out all the time and have issues with
their fans dying. I have had a power supply whose fan died without me
noticing, which would cause the power supply to overheat and shut off
periodically. This will leave you confused coming back to a power supply
that is working and a print that is paused in place.
If your breaker were to blow mid print, or your power supply were to give
out entirely, you will be left with a similar looking problem (power off on
machine, print failed mid print). Flip your printer switch off and go to your
breaker to see if any switches are flipped. If so, you know that it is an issue
with overloading the circuit.
And then the worst of all scenario is an actual blackout. This is not your
fault and can happen periodically in any city. Two times in the past couple
of years I had started extremely long prints when I experienced a blackout
that affected multiple city blocks. Every company and house was without
electricity for a short period of time, so the machines were powerless as
well.
One of these times it happened in the middle of the night when I was not
near the facility. When I came in the next morning everything powered up
just fine, yet every single print was frozen in place. The only reason I was
able to tell there was a blackout was by checking a time-lapse video that I
had been running.
If your printer is extremely important and cannot be shut off in a blackout, it
would be smart to invest in a backup power supply generator that can run
the printer for an hour while power hopefully returns.
NANO fuse issues
Finally, you may see similar issues, but some parts of the printer will still
power on when it is a NANO fuse issue. If your printer turns on, yet either
the LCD screen doesn’t work or some other strange part is not working –
preventing parts to complete – there is a chance you have a blown NANO
fuse on your board.
I go over this in full detail in the “LCD Blank or Dark” chapter. I have only
had this problem on Lulzbot TAZ machines with a Rambo board, so make
sure you know if your board requires NANO fuses.
Summary of Fixes and Precautions
Make sure your G-code was exported properly and re-slice if
needed.
Check connectivity of printer to raspberry pi to the internet. Any
disconnections in that chain will cause this type of failed print.
Or
Check to make sure your SD card is not freely moving and remains
connected throughout the print.
Check to see if power supply is working and fans turn on when hot.
Make sure you are not overloading any circuits.
Check with neighbors if experiencing a blackout.
Have extra NANO fuses on hand if your board requires them.
Quality Options
The quality, and amount of time to print, will vary based off of two factors –
your nozzle diameter (line width) and the layer heights you are printing at.
Below we will take a look at a few of these options.
Nozzle diameter

The nozzle
diameter will determine the line width of your print segments, which will
affect the tolerances in the X/Y direction. While many people prefer to
slightly tweak their line width from their nozzle diameter – I normally keep
it the same. I have been experimenting with increasing by 10% to good
results (as in printing 0.44mm line width with a 0.4mm nozzle). Any part of
your print that is thinner than your line width will not be printed, so you can
imagine how a thinner nozzle diameter can lead to a higher quality print.
The biggest issue with this comes with the print time required. The fact that
you have to slow your print down to prevent nozzle clogs, that you have to
print at lower layer heights, all along with the actual lines being thinner,
your print can be exponentially longer.
The general rule of thumb is to allow for a clearance of ½ the nozzle
diameter for parts that mate together, though as you see in the “Parts Not
Mating Together” chapter, it is smart to print your own tolerance test to see
what your clearances should be. You should be able to print with tighter
clearances though when using a thinner nozzle diameter.
When printing with a very small nozzle you will need to be using a geared
extruder. You need the proper amount of torque to push through 0.15mm or
0.25mm diameter nozzles. It is also smart to do this on a direct extruder vs.
a Bowden, since most Bowden setups will have a rough time pushing
through an extremely fine diameter nozzle.
Personally, I have standardized to using 0.25mm, 0.4mm, and 0.6mm
nozzles. It seems that the 0.15mm nozzle is very hard to dial in and takes an
extraordinarily long amount of time to print with, and the 0.8mm nozzle is
just too low of tolerances for what I am looking for. The only time I have
used a 0.8mm nozzle is when printing in vase mode, including when I try to
print transparent prints with PolySmooth. I have printed with a 1.4mm
nozzle on an E3D SuperVolcano, but that was only to test for a video, and I
have no real applications for it.
I have a couple of videos going over printing in different nozzle diameters
at my YouTube channel – The 3D Print General – if you would like further
information. The most recent one is titled “3D Printing with Extremely Fine
Nozzles” and it covers a ton of information on quality options and
limitations in FDM 3D printing.
How the nozzle diameter effects layer
heights

As stated
elsewhere in the book, you have a range of layer heights that will result in
reliable prints based off of your nozzle diameter. Essentially, you want your
layer heights to stay within 25-75% of your nozzle diameter. This means a
0.15mm nozzle should print roughly within 0.04mm – 0.11mm layer
heights, and a 0.8mm nozzle should print within 0.2mm – 0.6mm layer
heights.
When you go outside this range, the extrusion reliability and quality will
often go down. When you try to print with a small nozzle with too large of
layer heights, you will surely clog and grind filament more frequently, and
when you try to print too low of layer heights on a large nozzle, you won’t
be printing at quite the tolerances and quality that you could with a proper
nozzle diameter.
Layer heights

(Remember you
can email me at [email protected] with proof of purchase for high
def photos and color PDF)
Layer heights refer to how thick each individual layer is in the Z-direction.
Large layer heights reduce the quality in the Z-direction, but allow for a
much faster print. When printing at the same speeds with same nozzle
diameter, a print that is 0.2mm layer heights will take half as long to
complete as the same print with 0.1mm layer heights.
It seems that the speeds you can print at with a standard extruder/hotend
setup works on a bell curve. You need to slow down your print as you go to
very low layer heights and when using a small diameter nozzle in order to
prevent bottlenecking and nozzle clogs. You also need to slow down your
print speeds when going with a very large nozzle with large layer heights in
order to get the proper viscosity. If you print too fast with large layer
heights and nozzle diameters, the particular material may not have enough
time to melt.
For example, the standard E3D V6 hotend is advertised at printing up to
15mm3/s. This can be remedied with a hotend meant for this - such as the
E3D Volcano. The E3D volcano advertises printing up to around 40mm3/s
– meaning you can print much faster with larger nozzles and layer heights.
It seems I can print with the fastest linear speed on my standard V6 setup
with a 0.6mm nozzle at around 0.25mm layer heights. Once I bump up to
the 0.8mm nozzle I need to slow down my print speeds, and the same is true
when moving to a 0.4mm or 0.25mm nozzle. The larger nozzle will likely
still allow the print to finish faster even with the lower print speed due to
the additional volume of material that is being deposited with each move.
For over 90% of my prints I have standardized to a 0.4mm nozzle. I have
this nozzle in hardened steel and will print the vast majority of my prints at
0.1mm – 0.25mm layer heights with this 0.4mm nozzle. This will work for
the majority of 3D printing applications.
Running Out of Filament
This problem is by far the easiest to diagnose but also one of the most
frustrating when it occurs. You can think you have enough filament for that
400 gram print, when 20 hours in, with only 10 layers left, you run out of
material.
You can avoid this by taking these precautions:
 Weigh an
empty spool
It is always good to have the weight in grams of an empty spool for the
filament manufacturer you are using. These do have tolerances, but it is a
good starting point.
After you have the weight of an empty spool you can then weigh the spool
you are about to use for your next print. Subtract the weight of the empty
spool and you should have a rough estimate of how many grams of the
material are left. Make sure to provide a buffer of at least 20 grams to
account for tolerances in the spool itself.
Pause at layer height if you know you will
run out
If you are going to start a print with a spool that you know does not have
enough filament to complete, you can add a “Pause at Layer Height” to the
slice of your model. There is a plugin available for Cura and similar
features on Simplify 3D that will allow you to have the print pause at a
specific layer height and raise in the Z-axis, allowing you to switch the
filament out to another spool that can complete the remainder of the print.
This is especially useful for very large prints and you don’t have a full spool
available.
You can also use this feature if you would like the top portion of your print
to be a different color than the bottom.
Understand the density of the material you
will be printing with
When you use a slicing program it will give you an estimate of the amount
of material it will be using. If it gives you this number in grams, it will not
be accurate if you are using a material that is different than is in your
machine settings. If you are given this estimation without having to set
anything up, it is likely based on the density of PLA.
If you are given the estimation in meters and not grams, you will have to do
a minor calculation to find out the estimation in grams for your material.
PLA is 1.25 grams per cubic cm. If you were using 1.75mm diameter
filament, one meter of filament would be 2.41 cubic cm in volume.
1 meter of PLA 1.75mm filament would then be equal to 2.41 x 1.25, or
3.0125 grams. A 1,000 gram spool should be roughly 331 meters.
Using that 2.41 cubic cm in volume for 1.75 filament, you can use the data
below to figure out how many grams your material expects to use.
Density of material
PLA: 1.25 g/ccm - 3.0125 grams per meter of 1.75mm filament
ABS: 1.04 g/ccm - 2.5064 grams per meter of 1.75mm filament
PET: 1.38 g/ccm - 3.3258 grams per meter of 1.75mm filament
Most Nylons: 1.13 g/ccm - 2.7233 grams per meter of 1.75mm filament
The same is true for 2.85mm filament, you would just use 6.38 cubic
centimeters as the volume per one meter of filament.
If you are using Octoprint, you can also try installing the Filtracker plugin
which uses unique QR codes to monitor remaining filament length and
provides alerts when attempting to print an object without enough filament
remaining.
Use a filament runout sensor
Many printers now feature a filament runout sensor. You can purchase one
as well, it would just require you to do some tweaks to your firmware.
These sensors are very inexpensive and work in a way that they pause your
print when filament is no longer running through it. This means if your print
runs out of filament while you are away from the machine, you will come
back to a print that is paused with the hotend off of the print. You can then
change the material to a new spool, and click “resume”.
If you are consistently running large prints, where running out of filament is
a frequent occurrence, it would definitely be smart for you to invest in one
of these. TH3D has an inexpensive filament sensor called the EZOUT
which can be retrofitted to most machines very easily.
Summary of Fixes and Precautions
Weigh your spool before starting print.
Add settings to pause at a layer height to allow you to switch
filament if you know your spool does not have enough.
Know the density of the material you are using to calculate the
estimated amount of grams for your print.
Use a filament runout sensor.
If you are running Octoprint, try out the Filtracker plugin.
Settings Issues
This is a very vague chapter since it can deal with a variety of issues related
to having a clean print with the proper dimensional accuracy. Every single
material by every single manufacturer on every single machine will have
slightly different slicer settings in order to achieve the highest quality print.
That being said, I go over my personal settings for each material in
“Material and Their Settings” chapter in this book, and Nicolas from
Polymaker goes over in detail the idea behind material science in his
chapter. I sincerely suggest everyone reads that “Material Science” chapter,
since fully understanding it will help you to dial in your slicer settings
without even reading this chapter.
When covering this chapter in my first edition, I went over the old Cura –
Version 15.04.6 to be specific. Since that first book, Cura has entirely
redone their interface, along with including the ability to tweak just about
anything you can think of. I originally only covered Cura settings because it
was the best free slicer in my opinion, but as of their continual updates, I
find it better than almost any paid option as well.
Many makers prefer Simplify3D, but over the past two years I personally
feel Cura offers just as many options as Simplify does, and they seem to
update it even more frequently than S3D.
It may take a little while to get used to everything, but just about anything
you want to tweak is now available. That is why this chapter is such a long
and all-encompassing one.
Printers such as Zortrax, MakerBot, and others will require their own slicer
and not have these options, but you really should not be experiencing any
settings issues on those machines when using their proprietary material.
I will specifically be using Cura 4.0, but they are frequently releasing
updates with increased options.
The following examples will be with printing in PLA on a direct drive
machine with a gear ratio, though you can get more specific settings in the
“Material and Their Settings” chapter. If you would like some further detail
you can always visit my 3D Print General YouTube channel which goes
more in-depth on a couple of these options.
About Using Cura 4.0 and Newer
In order to see expanded options, make sure you are in the “Custom” print
setup, and not “Recommended”. You can save profiles for specific materials
and qualities, but we will just be going over what each option does.
You can then click on the gear icon next to any section to option the
expanded settings. When in the custom selection you can choose exactly
what options you want to tweak. For anything you are not sure what it does,
you can always scroll over it to be given a definition. I will personally only
be going over the options I tweak, because there are literally hundreds of
settings available.
 Quality
All of the factors I will be going over in this Quality section are the same
for both a Bowden and Direct drive printer.

The layer height of your print is very

dependent on the nozzle size of your printer as well as the quality of the
print you will like to achieve. A print at 0.1mm layer heights will take four
times as long as one at 0.4mm layer heights, with the same nozzle diameter
and printer speeds. You can get up to roughly 75% your nozzle diameter in
layer height, but remember that you sacrifice quality for time the higher you
go with the layer heights. You can also achieve as low as roughly 25% the
nozzle diameter without lowering your results.
Changing your layer height should not affect the amount of material you are
using, just the time involved to print. The longer the print though, the higher
the chance of experiencing a failure at some point. Not only will the print
be longer due to the smaller layer height, you will actually have to run your
extrusion speeds slower as well for a clean print.
The layer height is also affected by your Z-Axis leadscrews/threaded rods.
The diameter and pitch can affect the quality due to where your carriage is
on its rotation. There is a handy calculator over at
www.PrusaPrinters.org/calculator if you don’t want to do any math. You
just choose your Motor step angle (labeled on your Z axis motors), your
desired layer height, and your leadscrew pitch. Most of my machines are
1.8° step angle and a leadscrew pitch of 2mm/revolution on an M8
leadscrew. This means I can tweak my layer heights on a 0.01mm basis
without any issues. But if you have an M5 threaded rod with a pitch of
0.8mm/revolution, you will have to tweak on a 0.014mm basis for best
results. This means instead of 0.25mm layer heights, you should actually go
for 0.248mm or 0.252mm.
This is a bit technical and will definitely lead to cleaner results, but I have
printed outside of these suggested ranges in the past without much of a
difference. This is for when you want to make sure everything is as tuned in
as possible.
The Initial Layer Height is actually for bed adhesion more so than quality.
This allows you to have a thicker first layer in order to make sure
everything sticks properly. This number should always be at least as thick
as your normal layer height, and should only be increased up to 75% of the
nozzle diameter. I always take advantage of this because getting the first
layer to stick is easiest with a thick first layer.
This is a big reason dealing with small nozzles is so difficult to get the first
layer to stick properly. I have used a 0.15mm diameter nozzle before and it
took me over a half hour of restarting the print to get that first layer Z-
height distance correct. This is because the thickest I could print my initial
layer height at is 0.11mm after factoring in the RepRap Calculator
limitations. You can imagine that you have to be much more precise on that
first layer when printing at a 0.11mm layer height vs. 0.3mm.
The Line Width is just your nozzle diameter. Many makers suggest slightly
tweaking this, so you can play around with what others suggest, but I
personally always use the nozzle diameter for the line width I want to
achieve. If you want thin 0.25mm line widths, I would highly recommend
using a 0.25mm diameter nozzle instead of just tweaking this for a 0.4mm
nozzle.
There are roughly a dozen other settings you can tweak in Cura under
Quality, but I personally do not change any of them, since they all deal with
changing the line width of specific sections of the print. There may be
particular applications in which you want to do this, but I always stick to
the line width of the nozzle diameter I am using.
The 3D printing community is always learning and growing when it comes
to how you can change your slicer settings to improve your print, so playing
around is encouraged. Whenever I see improved results, I make sure to
factor them into my future prints.
Shell

Within the shell section you can tweak how

your outer walls and top/bottom layers are printed. The first option I have
open is the Wall Thickness. The wall thickness should always be a multiple
of your nozzle diameter (or rather your line width) and should be as thick as
required for your individual part. Unless printing something in vase mode
(spiralize the outer contour in special mode), you will almost always want
at least a minimum of two shells (3-4 on very small nozzle diameters). This
is not only for strength, but for infill overlap to make sure the outer surface
is not deflected by the infill.
I personally print shells at 0.8mm for my 0.4mm nozzle, and 0.75mm for
my 0.15mm nozzle. Anything less than this and the part will be too brittle.
If your particular part requires strength from the outer direction, such as
when I print skateboard wheels, you can increase the shell thickness rather
than increasing the infill percentage, since it needs strength in that direction.
On the many skateboard wheels I have tested and worked with, I increased
the wall thickness until it was 100% filled via shells. This is why it is
important to understand which direction your part requires strength in
before choosing to increase infill percentage, wall thickness, or both. For an
average part I will keep this to a multiple of 2-3x the nozzle diameter, with
a minimum of 0.75mm.
Many people prefer a minimum of 1.2mm thickness for shells, so it is up to
you to determine what you think will work best here. Just do not go too thin
or your part will be weak.
The Top/Bottom Thickness is how many layers of 100% fill will be left
before and after the infill is printed, and is a multiple of your layer height.
This number will have to be tweaked depending on how much infill you use
and how thick your model is, but I always suggest having a minimum of
1mm in top layers. This is to make sure you do not have a “pitted” top in
which you can see the infill below. While this is very important to keep the
top layers at a minimum of 1mm, if you are still seeing a pitted effect, it is
probably better to just increase the infill percentage. The bottom layers are
not as important since they do not have to cover an overhang. I still will do
at least 4x the layer height, with a minimum of 0.6mm being laid down for
bottom layers.
Remember that the top/bottom thickness is going to be working off a
multiple of your layer height. So if you are printing 0.3mm layer heights,
you will need to round to the nearest thickness in relation to that. Rather
than having 0.8mm thickness for the bottom, you would want to go up to
0.9mm.
The Top/Bottom pattern is as it is described, and I almost never tweak this
from “Lines”. “Zig-Zag” may have some applications, but I don’t know
when you would want to use “Concentric”.
Optimize Wall Printing Order reduces the number of retractions and the
distances travelled and will benefit most parts. It should improve speed and
quality on most prints, but if you are starting to see defects going up in the
z-direction of your print or an increased slice time – turn it off.
The Z Seam Alignment is where the printer will decide to go up to the next
layer. If you have ever seen a seam going up your print, it is because your
printer was moving up in the Z-direction to start a new layer right at that
spot, for every layer. These seams are just about impossible to avoid
entirely, but you can determine where they are placed. If you are printing a
part with corners or lots of curves, you will likely want to choose “Sharpest
Corner” for the highest quality. For a smooth or cylinder shape, you may
want to choose “Random” for the best quality, so there isn’t a giant seam,
considering there is no sharpest corner. “Shortest” will choose the fastest
printing method, which will likely lead to a seam on one part of your print,
but it will definitely print a bit faster.
Ironing is a very unique setting that you definitely will not always want
turned on, but I am showing my settings above for when you do want to use
it. It is also the only option in this section that will need to be tweaked
whether you are using a Direct Drive or a Bowden (Bowden will need to
run closer to the Cura recommended settings, while Direct Drive has to be
bumped up to what is shown in the previous photo). Ironing was originally
a Cura Experimental feature that was moved to the “Shell” section.
Ironing is a very cool feature in which I cover in-depth on a video on my
3D Print General YouTube channel. It has your nozzle go over the top
surfaces an additional time, but without extruding any material in order to
melt the plastic on top further, creating an extremely smooth top surface.
This will ONLY work on parts that have flat tops and is not needed on parts
that are entirely curved, but if you ever wanted to remove those pesky layer
lines on top surfaces, you can now do so.
This will definitely need honing in for your particular machine, as it took
me a couple dozen prints to get everything you see dialed in for my direct

drive printer.
Personally, I do not use this setting very often, since the results can often
vary depending on how much surface area has to be covered. Use this
setting at your own discretion and play around before printing a part you
need to come out clean.
Infill

This section is what you will want

to change if you need to increase the strength of your part in the top/bottom
direction, reduce the “pitted” effect on your print, or decrease the time
required for your part to print. Everything explained below will be the same
on both a direct drive and Bowden extruder.
You will have to recognize how thick your part is before realizing how
much infill you require. If your whole part is made up of thin walls, it is
likely the infill percentage will not make any difference at all, since the
majority of the print will be filled via shell walls. But if you are dealing
with a large block, it will be a deciding factor in a successful or
unsuccessful print.
Most models can print successfully at 10% or lower, but not for large/thick
models. Think about the top surface contour of your print. If it is a flat top
that needs to bridge a large gap, you are likely going to need to increase this
infill to a minimum of 20%.
Personally, most parts that I print that do not need to be mechanically
strong, I print at about 8%. So make sure you know your geometry and
application since you can save a lot of time and material printing by
reducing this number.
To be honest, most parts you print will not require higher infill than 50%,
and you will get diminishing results when you go much higher than that.
You will use a ton of material to print at 100% infill and your printer will
take a lot longer to complete, when you will likely get a lower quality print
without much increased strength. I will rarely print something at 75% infill
and almost never at 100% (other than just for testing materials). The
majority of my decorative or prototype pieces are at 8-15% infill, parts I
mechanically use are 20-40% infill, and very strong parts I go around 50%.
There are many parts that can actually be printed below 10%, even 0%, if
the geometry calls for it and you put enough top layers in your Top/Bottom
Thickness.
The Infill Pattern refers to the structure shape of the infill. While you are
given plenty of options, I almost always keep this on “Triangles”. Hexagons
are one of the strongest shapes in this regard, but your printer nozzle has to
go over the same line twice in order to actually make the shape. Because of
this (and because Cura does not offer the Hexagonal option), I go with the
second best shape being a triangle. Triangle infill can be printed extremely
fast and still has a lot of strength properties.
Others online say they get great results from some of the other options, I
just stick with “Triangles”. Feel free to play around with these and see if
you prefer one over the other.
Infill Overlap Percentage is the percent that your infill overlaps onto the
shell walls. When this number is set too high, along with not having enough
shell walls, you can get what I called a “Veiny” print in the diagnostic
section, and too low of a percentage can result in infill that rattles around
detached from the walls, decreasing the strength of your part. I almost
always reduce the standard set by the slicer and prefer a number around 8%
or 9%. This, in combination with 2-3 shell walls, will result in a strong print
without any infill veins showing throw the outside.
Please note this is for opaque materials. If you are dealing with a translucent
material you are going to need to increase the shell walls drastically if you
do not want to be able to see the infill. That is not a veiny print, but rather a
print you can see through.
Another way to reduce this “veiny” look is to check off the “Infill Before
Walls”. This makes sure your infill prints before your shell walls, reducing
the likelihood you will get a “veiny” print.
Finally, the infill layer thickness is just what it sounds like. For well over
95% of prints I just keep this the same as the rest of my layer heights. But
let’s say we are printing a large detailed print in which the strength does not
really matter. We may set our layer heights to be 0.1mm, but the quality
only matters on the outside walls. You can set your infill layer thickness to
be 0.2mm, meaning that it only prints the infill every two layers –
drastically speeding up the time required to print. This could save you hours
of print time.
here are at least a dozen other options available in which I personally do not
tweak in this section.
Material

Printing Temperature is very

straightforward and will be the temperature in which your hotend is set to.
This is entirely dependent on the material you are using and the printing
temperature will be tweaked depending on the nozzle diameter and layer
height. As covered thoroughly in the “Nozzle Clogs” chapter, if you have
the hotend set to the wrong temperature, you can have quite an annoying
cleanup on your hands. Be sure to refer to the “Material Science” chapter to
understand a bit more about melting points and what may work for different
filaments. Below are generic print temperature ranges for different
materials.
PLA: 180°C – 220°C
ABS: 225°C – 235°C
PETG: 245°C – 2552°C
CFR – ABS: 245°C – 253°C
Cheetah by Ninjatek: 223°C - 235°C
Ninjaflex: 223°C – 235°C
PCTPE: 232° - 235°C
Nylon 910: 245°C – 252°C
Polycarbonate ABS: 267°C – 275°C
As mentioned elsewhere, you may need to tweak these settings depending
on the manufacturer you purchase from, and the machine you are using.
Bed temperatures for specific materials are covered in the “Bed Adhesion”
chapter, so below you will find the generic temperature ranges I like to use
for extruding different materials. The range is in reference to the differences
in nozzle diameter, layer height, and manufacturer. This is all explained
further in the relevant “Material and their Settings” chapter of this book. I
personally have my build plate temperature for PLA set to 55°C now
instead of 60°C in order to help reduce “Elephant Foot”.
The diameter is the diameter of the material and extruder you are using.
This will either be 1.75mm or 2.85mm depending on your setup. If you
purchase from a subpar manufacturer, you may get tolerances too large, so
make sure you stick with what has been reviewed and tested to work. Most
machines out there are 1.75mm today, but some companies such as Lulzbot
still use 2.85mm.
Assuming you have your E-Steps dialed in, as explained in the “Over and
Under Extrusion” chapter in this book, you will not need to change the flow
from 100%. But, if you wanted to change your extrusion rates on the fly,
you can change it in the flow section. 101% will extrude 1% more than
what your current E-Steps are set to.
This is the section you can change if you are unable to flash your machine
or give G-code commands. You can reduce the number accordingly if you
are unable to change your E-Steps. This isn’t ideal but it should have the
same results.
Retraction should be enabled on the vast majority of your prints and will
need to be tweaked based off of the material and if you are using a Bowden
or Direct Drive setup (with the numbers shown being for PLA on a Direct
Drive). Bowden machines will need higher numbers than I am showing.
Having your retraction dialed in is the number 1 way to reduce the
stringiness and “hairy” prints. There are a few models that may require
retraction turned off, but you will almost always want it on.

The print on the

left is with retraction turned off, and the right is with it turned on to the
settings I have shown above. Please keep in mind this model is designed to
torture test your machine, and you may not need quite as high of retraction
settings on every model. Going too high of retraction may result in an under
extruded part.
The retraction distance refers to how far the material goes when retracting,
retraction speed refers to how fast, and minimum travel refers to the amount
of travel required for any retraction to happen at all. If you have a part with
extremely small pegs (for instance - a very small fence on an architectural
model) and they are still coming out “hairy” after using the settings I
example, you may need to decrease this minimum travel number.
Bowden machines will need these numbers bumped up, as explained in the
“Material and their Settings” chapter.
Particular materials also require different retraction settings. I have found
that PETG is far stringier than PLA, requiring higher retraction settings.
You can understand this further in the “Material Science” chapter.
It is very easy to clean up a minor amount of stringiness via a heat gun and
a razor.
Speed

All of the numbers you see will need to

be tweaked for Bowden machines, as explained in the “Material and their
Settings” chapter. But these speeds will also have to be tweaked depending
on your extruder and hotend setup. If you are using a non-geared extruder,
you will need to run much slower than if you have a geared one. I am
personally using a Bondtech BMG dual drive extruder with an E3D V6
hotend, so I am able to extrude fairly well at speeds even above what you
see.
These are the settings that will be most tweaked depending on your
machine, quality, and the material you are using. As mentioned elsewhere,
if you are experiencing issues with the speed your machine is printing at,
you should reduce it so that it is no faster than 100x the nozzle diameter. If
you have a well-built geared extruder machine that is printing at mid-range
(~50% nozzle diameter), you can actually get this number to 300x the
diameter of the nozzle, but I would not recommend anything near those
speeds if you are experiencing issues or extruder motor skips or rattling of
your machine.
Keep in mind that the amount your hotend can actually successfully
extruder will also determine your maximum print speeds. An E3D Volcano
hotend can push out a lot more volume than a standard E3D V6, meaning it
can have a higher print speed.
You should definitely see the video I published entitled “How Fast Can You
3D Print?” where I cover all of these details which you should know.
The infill speed should almost always be the same speed as your print
speed, while your outer wall should be slowed down a bit to make sure it
has the best surface quality. You will also want to make sure your initial
layer is about 50% your print speeds, with it tweaked even lower if you are
having difficulty getting that first layer to stick. A generally good range for
this is anywhere between 15mm/s and 25mm/s depending on the material
being used. There is no need to go fast on that first layer since it is the most
likely layer to make the rest of your print fail if it does not get laid down
perfectly.
Your travel speed is how fast the carriage moves when not extruding
filament, and this can be bumped up fairly high, especially on Bowden
machines. As long as your printer isn’t rattling, you can likely get up to
100mm/s without much of an issue, even higher with a light carriage. I have
recently been playing around with speeds of over 200mm/s since it should
reduce oozing and will not affect print quality, but keep in mind these
speeds may not even be reached without a high enough acceleration.
Acceleration refers to how fast your printer gets to your print speed, and
jerk refers to the initial speed your extruder stepper will start at after a full
stop. Your printer will accelerate at the highest rate possible up to that speed
and then the acceleration value will take over at speeds above what is set for
the jerk variable. In physics, “jerk” refers to something else, but this is what
it refers to in 3D printing.
You can set your acceleration controls in your printer firmware, but it can
always be tweaked right here in Cura. If you have ghosting/ echoing in your
prints, a rattling machine, or ugly outer surfaces - reduce your acceleration
and jerk. Reducing these will obviously slow your print down, but it will
help immensely. Start with the numbers I show above for a direct drive
machine and increase them if everything turns out fine. If not, there is likely
something else that is wrong (such as a loose carriage or other issue
explained in this book).
This is also where limitations for your machine come into play. You will
never reach your print speed if your acceleration is not set high enough, or
if there is not enough room to actually accelerate and decelerate. You can
set your print speed to 1000mm/s, but without the space and high enough
acceleration, it will never actually be reached.
As I went over further in my YouTube video mentioned above, I personally
prefer to wait a bit longer for my print to complete and have my
acceleration and jerk settings very low in order to guarantee a clean and
successful print. You will likely hear others printing much faster than this,
but if you are using a machine that cost under $1000, it is likely going to be
hard for you to achieve those results.
Travel

Combing refers to the printer head

following the path of the print rather than attempting to clear gaps. This will
help prevent “hairy” sides of a print. When combing is set to “off”, the
extruder moves straight from the starting point to the end point and will
always retract. Most of the time I will leave combing to “all”, but there are
specific times when I need combing turned off. When I work with very
large layer heights – anything 0.4mm or higher, I will turn combing off.
This is because the layers are so thick, that when the printer travels from
one point to another, it will run into the infill. Even when I have “avoid
printed parts when travelling” checked, the printer seems to want to run into
the infill lines. You won’t really notice this on low layer heights.
When combing is turned off, it will retract, do a z-hop, and then travel to its
next position. As mentioned – this can add to your ooze and hairy issues,
but sometimes it is needed. For instance, when I was using the E3D Super
Volcano with a 1.4mm nozzle at 1.0mm layer heights, the print was just
about impossible when combing was turned on.
Both avoid printed parts when traveling and avoid supports when travelling
refers to what you think it would – the printer head steers clear of your print
while moving from section to section. This will clearly add to print time
considering the print head will not be taking the fastest path, but it will help
avoid knocking your parts over. While it is not required to be on, I almost
always keep both of these boxes checked.
Z hop when retracting refers to the amount the printer will raise in the Z-
direction after retracting, as to not knock over small pieces when traveling
between sections. If you are constantly getting parts knocked over even
though you took all of the precautions mentions in the “Bed Adhesion”
chapter, you may need to increase this number. The larger the nozzle
diameter and layer height, the more you will likely want to increase this.
Also refer to the “Parts Being Knocked Over” chapter if required.
If you ever hear some random loud clicks or noises during your print that
you are having trouble figuring out where they are coming from, it may be
from your nozzle hitting the print or support as it goes over it. Even if your
print does not get knocked over, you will want to add a Z-Hop height and
increase it until this does not happen. Almost every print you will want at
least a minimal Z-hop height. For the vast majority of my prints, I have my
Z-hop set to the same as my layer height and will tweak accordingly if
needed. If the clicking continues – turn combing off.
Having these previous sections all turned on should definitely help with
reducing issues related to parts being knocked over.
Cooling
Cooling refers to when your active cooling fan will be engaged. Refer to the
diagram of a 3D printer in the beginning of this book to know exactly which
part I am talking about. This is crucial for getting the cleanest print possible
on many different types of materials. If you are printing PLA without an
active cooling fan, it is certain you are not achieving the best results you
can.
This is not true though with specific types of materials, since you will
reduce your layer adhesion. You need to know what material you are
working with in order to understand if you need an active cooling fan on or

off. You do not want your active

cooling fan to blow on your first layer since it can hurt with your bed
adhesion. This is why I set the “Fan full on at height” number to 0.5mm –
0.6mm on most prints. It is rare that a material will call for a fan speed in-
between 0 and 100%, so it is normally set to 100% on most prints.
If I am printing a large ABS part that comes to a small point, I may actually
turn on the active cooling fan and turn this number to the height in which
the point starts. If you have an active cooling fan on a medium-large ABS
part, or any other high-warping material, it is likely you will end up with a
failed print. This is why you will want the active cooling fan turned off for
the majority of ABS prints, unless the geometry calls for it.
This active cooling fan can also play into your nozzle not maintaining a
specific set temperature if the fan is blowing directly on your heater block,
or if you are not using a silicone sock.
Minimal layer time refers to the amount of time required before starting a
new layer. If a layer completes its tool path faster than this amount of time,
your printer will pause until the time has passed before starting the next
layer. This setting should almost always be accompanied with a “Lift Head”
that you see right below it.
This “Lift Head” does just as you think it would. If a layer finishes faster
than your minimal layer time, it will lift your extruder and pause until the
correct amount of time has passed. For the example above, if a layer takes
two seconds to complete, your nozzle will lift and remain there for one
second before starting the next layer. This can add to the stringiness of your
part but will make sure your top section is not a melted mess.
Most of the time you will not require this number to be higher than 5, since
5 seconds is long enough for the vast majority of materials to properly cool.
If set to 1 second or lower, you will get very ugly, melted pointed tops. Any
model that doesn’t come to a single point will not even be affected by this
number, unless set very high. If you are just printing one skinny part, you
will notice that it may come out hairy due to constant head lifting from the
minimum layer time not being hit. In these instances, you can print 2 or 3 of
the model without increasing the print time at all, and may actually result in
a cleaner print as well.
Support

The overhang
angle for support refers to the minimum angle required before support
material is laid down, vertical being 0°. This may seem a bit confusing so it
is best described by the image below:

Certain slicing
software, such as the one for a Zortrax machine, will go in the opposite
direction, having horizontal be 0°. We will be using 0° throughout this
book, but if you are using an alternate slicing software, you may need to
invert the settings I am describing in this section.
The general rule of thumb is support material will be needed on overhangs
of 45° or greater. PLA can actually cleanly lay down angles of a higher
degree if everything is set up properly and you are running an active
cooling fan. There are models you can find on www.Thingiverse.com that
allow you to test the highest angle your printer and material can achieve
without supports. Just search for “overhang test”.
Materials may actually be able to achieve different overhangs without the
need for support depending on your other slicer settings, particularly your
layer heights. This is covered a bit in the “Materials Science” chapter, as
well as a video on my YouTube channel titled “How to Avoid Needing
Support Material”.
For ABS, I have this number set to 45°, and I will hone it in for any angles I
notice scarring. In general, for most materials I will not go lower than 40°
or higher than 60°.
You will usually want your support placement to be “Everywhere”, unless
the model you are printing was designed to only require “Touching Build
plate”. “Touching Build plate is what you assume it would be, it will only
place support structures where they can easily touch the build plate. This is
often not desired on most prints.
The support pattern I almost always have set to Zig Zag, though you can
use Lines to save filament, or Grid to increase quality of the print, but when
using the Support Interface explained later, it won’t make much of a
difference at all. The support density should be tweaked as well if you are
not using the support interface.
Please refer to the “Experimental” section near the end of this chapter to
find out how to reduce your support material even further.
Essentially, the support interface generates a dense interface between the
model and the support creating a skin at the top of the support in which the
model is printed, and is a newer feature on Cura. This is automatically done
on Zortrax machines and is a great addition to Cura. In the first edition of
my book this was not available yet, so I went over my support settings just
using the normal support lines.

As you can see in

the image above, there is this support interface in-between the normal
support and the model. The image may be hard to see on your printed book,
so don’t forget to reach out to me at [email protected] for high
definition color photos.
This means that the support pattern and support density will not affect the
underside quality of your print when having this turned on, so I will reduce
my support infill to as low as I can get it. Too low and your support may get
knocked over during the print, which is why I like to keep mine at 10-12%.
I use this support interface on almost all main materials, but if you are using
flexible filaments or materials with absurd layer adhesion, you will likely
want this turned off. Removing parent support material can be quite
difficult on many unique materials.
The numbers you see are what works for me on PLA for both a direct drive
and Bowden extruder, and may need to be tweaked further for your
machine.
If the underside of your print is still ugly after using my suggested starting
points, either increase the support interface density and/or decrease the Z
distance for support. If it is proving very difficult to remove this support
material based off of my suggested settings, you should increase the Z
distance for support. The support X/Y distance of 0.8mm seems to work
just fine on almost all models and materials, and any closer the support
material may be difficult to remove.
I recently created a video titled “Detailed Cura Support Settings” where I
take a look at every aspect of this and show how it makes a difference in
your prints. I spent a while on this video making sure to cover everything,
so I really suggest checking it out if you are having lots of support
difficulties.
Build Plate Adhesion

Having a skirt will allow for the

material to purge a bit at the beginning of your print and for you to double
check that the bed is level, but will not help to anchor your print. You will
only need one line and you will want the start distance far enough from
your print so that it does not interfere. A distance of 3mm works fine.
For roughly 90% of my PLA prints I only use a skirt, since there is no real
problems with warping. But if you ever need a part to have enhanced plate
adhesion, change this to a skirt.
If you are having difficulty getting your part to stick to the bed, or if you are
printing with a high warping material, you will want a Brim, as mentioned
in the “Bed Adhesion” chapter. If you choose “Brim”, it will add the
number of lines you choose touching the perimeter of your print. These
lines are as thick as the line width you are using (which I keep as the nozzle
diameter). So if you choose 15 lines and are using a 0.4mm nozzle, you will
be adding 6mm of brim around your print.
This brim acts as an anchor to prevent warping and help bed adhesion, and
is removed post print. I have “Brim Only on Outside” checked for most
prints, because it will prevent extra brim from being laid on holes on the
inside of your print, and only be printed on the outside to act as an anchor.
Keep in mind that a brim can be difficult to remove cleanly from some
materials, one being PLA, which is just another reason I keep my settings to
only be a skirt for the majority of PLA prints. A brim on ABS is much
easier to remove than PLA.
Finally, your last option for platform adhesion, is to add a raft.
I honestly do not use this option often, but there are specific times I will.
Many printers, such as the ones made by Zortrax, will leave an easy to
remove raft on all prints. The Zortrax does it because the build plate is
perforated and would leave an ugly underside to your print if it didn’t.
Other printers make this standard because they do not have a heated build
plate. I will personally use a raft when I am battling with “Elephant Foot”,
as described in that chapter.
If you are printing a part that only has a lot of very small posts touching the
build plate, you may want to consider adding a raft. Material has a lot easier
time sticking to itself when printing than it does sticking to the build plate
on its initial layer. By adding a raft with specific settings, you can make
sure the bottom layers are nice and thick with plenty of adhesion, and then
stick your print to the top of it. You can then easily pop the parts off without
having to battle with cleaning off a brim.
These rafts are then removed after printing, but can damage your part if too
close, and can leave ugly scarring if your part is too far.

Special Modes

There are a few “special” modes

offered by Cura, but I will only use one on rare occasion: Spiralize Outer
Contour. Please make sure these two boxes are NOT checked for a standard
print. I am only checking them in the example above so you can see the two
options involved.
Spiralize the Outer Contour is basically “Vase Mode” for Cura. This will
make it so only the outer wall and bottom layers of your part are printed. No
inner walls, no infill, no top layers. This option should leave no seams on
your print.
You will only want to use this when you are printing a Vase or something
that needs similar properties. I have a Christmas tree that I printed large in
this mode that looks great, along with a couple of vases given to my mother.
I also use this mode when I need to print something transparent in
PolySmooth, as covered in my “Transparent 3D Prints” video. Other than
rare use cases like this, it is likely you will want to keep this option
unchecked.

Experimental
 This section is constantly changing
and is where “Ironing” once appeared a while back. I attempt to go over
some of these on my 3D Print General YouTube channel, but Cura is always
getting tweaked. I currently have 3 videos on experimental Cura settings, so
refer to those for further information.
I have tried a few of these but have found the most useful to be Coasting,
break supports in chunks, and conical support. Coasting is so useful that I
expect it to be moved out of the experimental section in upcoming updates.
I do not have coasting turned on for direct extruder prints, but always have
it on for Bowden machines.
Coasting replaces the last path of an extrusion path with an oozed travel
path. The oozed material is used to print the last piece of the extrusion path
in order to reduce stringing. If you are experiencing “hairy” or stringy prints
regardless of tweaking your retraction settings, you will definitely want to
try this out. In fact, I have this turned on for almost every Bowden print that
I do. The volume should just be your nozzle diameter cubed, and the
minimum volume before coasting will make it so coasting is turned off for
small areas. This is important to get to 0.8mm or above to prevent small
parts from looking under extruded. If that is happening to you, go ahead and
increase this number.
“Break Support in Chunks” does just as you would imagine. It allows there
to be less support material that is easier to remove. You want to be careful
breaking them into too many chunks, since you will just be printing in a
“line” pattern rather than “zig zag”.
“Conical Supports” is pretty awesome, as it allows the amount of support
material touching your build plate to be less, and then grow at an angle until
it is the size required for the underside of your print. If you go too low you
can be battling with too small of a surface area touching the build plate, but
the settings I have above work great. This can actually end up saving you a
lot of material and time on large builds.
A “Draft Shield” builds a wall around your print in order to help trap air
and reduce ambient air from getting to your print. This should, in theory,
reduce the amount of warping and delamination you experience, I just
personally have not noticed much of a difference at all. It may be worth you
playing around with.
“Fuzzy Skin” randomly jitters the outer wall so that the surface has a rough
and fuzzy look. This is a very rare use-case, but it works great to give
something a grippy feel that looks stronger than it is. I have personally used
this for handles on cosplay guns.
Adaptive layers is a very intriguing section, but I am unable to make it work
right. It makes it so that you have smaller layer heights for high detail
sections of your print, and larger layer heights for when detail is not needed.
This should, in theory, improve your print quality and reduce your print
time. The unfortunate thing it does not factor in is the need for different
printing temperatures and speeds for different layer heights. I assume that in
the future it will incorporate these things, but I personally do not use it for
my prints for this reason.
Settings on other slicing programs
Other slicing software may have these features in different sections, may
call them something different, or they may not have them at all. For years
Simplify 3D was the way to go if you wanted full control of your slicer
settings, but as of the last couple of years Cura offers just about everything
they do – free of cost. There are so many options available that I have well
over half of them turned off. You can spend a couple of weeks just doing
test prints to figure out what each one does, allowing for full customization.
I am definitely not paid by Cura/Ultimaker and have had zero contact with
them other than really enjoying their updates to the slicing software.
PrusaSlicer is also a new, free, slicer that is growing in popularity if you
want to try something else out.
Speed Limitations
Often, printer manufacturers will advertise print speeds that are either not
really possible, or will result in a subpar quality print. There are limitations
when it comes to printing fast, many of which have physical impossibilities.
There is no doubt that printing at larger diameter nozzles with larger layer
heights will result in a print that completes in a shorter time than their
counterparts, so this chapter will not really be covering this. This is in
relation to the speed your extruder carriage is moving.
NOTE: Please keep in mind I always suggest erring on the side of printing
slower, as you see throughout the rest of this book. I am just going to be
going over the limitations involved with printing top speeds.
Nozzle diameter limitations
This is a little vaguer than the rest of this chapter, but the diameter of your
nozzle will limit you on just how fast you can extrude. This is due to
bottlenecking between the extruder and the nozzle.
Just as with traffic when driving, attempting to squeeze material through a
very tiny hole will have its own limitations in speed. It is difficult for me to
give exact top speeds on this, but the smaller the nozzle diameter, the
slower you are going to have to print. While I am able to print just fine with
a standard V6 hotend on a 0.4mm nozzle at speeds of up to 100mm/s, I
have increased difficulties going with a smaller diameter than this.
Pushing 1.75mm filament out of a 0.15mm nozzle diameter is going to have
a lot of bottlenecking. With this extremely tiny nozzle diameter, I am forced
to go down to just 20mm/s print speed. Any faster than this will have a lot
of difficulty overcoming bottlenecking, resulting in a very under extruded
print, if it doesn’t just result in extruder skips or a nozzle clog.
A larger diameter nozzle will allow for faster extrusion without this
bottlenecking occurring, though you will need to read the next two section
to understand how that has its own set of physical limitations.
Hotend limitations
This is a physical limitation that is impossible to avoid. A hotend can only
extrude so much volumetric material per second. The material needs time to
heat up and become viscous enough to actually come out of the nozzle.
Many hotends have a rating for just what volumetric throughput it can
handle. The standard V6 hotend by E3D – likely the most common hotend
on the market - has a max throughput of around 15mm3/s. This maximum
throughput will change depending on the material you are using, but the
maximum it can handle is roughly that volume of plastic per second.
Based off of that max rating, you can do some math to figure out the max
speed the hotend can handle depending on the line width and layer height.
You can essentially figure out how much volume of material is coming out
per mm travelled. But, if this is a bit complicated for you, you can also
check out a calculator online by Print Industries
(PrintIndustrustries.com/pages/print-speed-calculator).
Based off of this 15mm3/s, the max speed for 0.2mm layer heights on a
0.4mm layer lines would be 240mm/s. This is far higher than you would
ever want to go for your 3D prints, but you can at least see the physical
limitations involved with a hotend. When bumping these numbers up to
0.8mm layer lines at 0.4mm layer heights, this maximum speed is down to
60mm/s (due to more volume being pushed out the nozzle per mm
travelled).
Mind you those numbers are pushing the hotend to the max. I would error
on the side of going for roughly 50% the maximum throughput rating for
your hotend. This means that with a 0.8mm nozzle at 0.4mm layer heights
on a standard V6, you shouldn’t go above 30mm/s speed. This is when your
hotend will really limit your maximum speeds.
If you plan on only dealing with a 0.4mm nozzle, then your V6 hotend will
not really be limiting you on your maximum speeds. It is when you want to
work with these larger nozzles that it will become a factor. And that is why
the E3D Volcano and SuperVolcano exist.
The Volcano allows for up to 3x the maximum throughput of the V6, and
the SuperVolcano allows for up to 11x the maximum throughput of the V6.
These are the hotends you want to use if you want to print big parts with
large layer heights. This way your hotend will not be the limiting factor on
you printing fast.
So, if you ever see a printer manufacturer advertising print speeds of
150mm/s, you need to question the capabilities of the hotend, and with what
nozzle diameter and layer heights they are referring to.
Please refer to my video titled “Taking it to the Extreme with the SUPER
Volcano” for more information on hotend limitations and testing out these
higher rated hotends.
Extruder limitations
As covered in the “Extruder Stepper Skipping” chapter, your extruder itself
is going to be limited to how fast it can spin. If you are using a non-geared
extruder, especially one on a Bowden setup, you will never come close to
printing at speeds where you actually require a higher rated hotend. When I
am using an inexpensive printer with a Bowden non-geared extruder, I am
really limited to just about 40mm/s max speeds when printing with a 0.4mm
nozzle at 0.2mm layer heights. Any faster and I will hear that annoying
clicking of the extruder motor skipping.
When going with larger layer heights and larger nozzle diameters I am
going to be forced to go much slower, due to the extruder motor needing to
push out more volume per mm travelled.
Ever since switching to the Bondtech BMG on a direct extruder setup, I
have never faced these limitations. I am sure there is a point where the
extruder needs to spin too fast, but even when using the SuperVolcano with
a 1.4mm nozzle and 1mm layer heights, I was still able to print 55mm/s
without any issues, but my extruder gear was spinning extremely fast. You
need to know the limitations of your extruder setup.
Acceleration/Deceleration
If you hear that someone is printing at 300mm/s without an immense
amount of modifications, you can almost be guaranteed they are never
actually reaching that top speed. This is because the hotend needs time to
accelerate to this speed, and then time to decelerate.
This is the main reason just doubling your print speed is not going to cut
your print time in half. Your print time is going to have diminishing results
the faster you set your print speed, in a pretty logarithmic fashion. This is
where your acceleration and jerk settings are going to come into play.
Your jerk settings are for the initial speed your hotend will instantaneously
start travelling at from a stop. This would mean if you set your jerk to
20mm/s, your hotend will instantaneously start moving at 20mm/s, and then
accelerate from there.
So if you have a jerk of 20mm/s and an acceleration of 1000mm/s2, it will
take your hotend 0.1 second to reach a speed of 120mm/s. This may not
sound like a lot of time, but you have to factor in that most 3D models
require a lot of starting, stopping and changing of directions. And your
printer can’t just come to a complete stop after travelling 120mm/s, it needs
to decelerate, taking roughly another 0.1 second to stop.
When we bump that number up to 300mm/s, we are talking about a time of
over 0.25 seconds to reach that speed with the same jerk and acceleration
settings. You can imagine how your printer may never actually have a
quarter of a second to accelerate and decelerate, meaning you would never
actually reach 300mm/s.
You could of course bump up your acceleration and jerk settings, but that is
when you are going to come into problems covered in the next two sections.
Frame of your machine
The frame of your machine is going to really limit you on how high your
acceleration and jerk settings can be. While Cartesian printers are the most
common machines out on the market, they are also going to be the
machines that limit you the most on acceleration and jerk.
And this is because on Cartesian printers your print bed is going back and
forth in the Y direction. This heavy, large print bed constantly accelerating
and decelerating is going to cause your machine to rattle. While this may
not be much with low jerk and acceleration settings, the higher you go, the
more extreme this is going to be. When I set my acceleration and jerk
settings very high, my entire table was rattling all over the place, to the
point things were falling over. You can see just what I mean on my video
titled “How Fast Can You 3D Print?”.
You can harness your printer to the print table, but your ghosting problems
are going to increase due to the lack of vibration dampening.
This is a major reason people prefer CoreXY and Delta machines. Delta
machines are far less common, but the one thing they have going for them
is the increased acceleration possibilities. Your printer really shouldn’t rattle
much at all even with very high acceleration and jerk settings.
CoreXY machines have pretty much become the preferred frame for most
makers out there, including myself. The fact the build plate is only moving
in the Z-direction means you will experience exponentially less rattling.
This lower amount of rattling will not only help to print tall skinny parts
and not have parts be knocked over mid-print, but it will also help you to
achieve higher acceleration and jerk settings without losing quality.
While I keep my acceleration to around 500mm/s2 on my Cartesian
machine, I can bump that to over 1000mm/s2 on CoreXY without any loss
of quality.
Print Quality
Just about everything covered above are actual physical limitations
involved with hitting high print speeds, but the one thing we haven’t
covered is print quality.
Assuming you are within the limitations of your hotend and extruder setup,
a high print speed will not really decrease your print quality that much. The
thing that will be decreasing your print quality the most is high acceleration
and jerk settings.
The biggest issue is ghosting, which you can see covered in the “Ghosting”
chapter in this book. Ghosting is mostly happening due to high acceleration
settings on a frame that is rattling a lot without vibration dampening.
If you don’t have a well-built frame, you have an increased chance of
experiencing Z-wobble, layer shifts, and parts being knocked over. There
are likely to be extra artifacts on your print that are hard to explain or fix
due to the difficulty honing in your retraction and other settings.
This is why I always suggest going slower in all settings if you are having
difficulty getting a clean print. I am sure you would be willing to wait a
couple extra hours to be assured your print will come out with the quality
you expect.
Stepper Motors Overheating or
Malfunctioning
This is a fairly broad printing failure but is essentially when one of your
motors is not turning properly or is overheating. Many of these issues are
covered in the “Layer Shifts” chapter in this book.
Stepper motors overheating
A stepper motor can be running too hot for multiple reasons. If you have an
enclosed printer and are running a long ABS print, not only will the stepper
motors be getting hot from standard usage, they will be trapped with
ambient air of 35°C – 50°C. Even if a print is being completed without any
issues, you do not want to run your motors too hot so that they can remain
as free of maintenance as possible.
Industrial grade stepper motors have magnetic cores which begin to degrade
when they reach temperatures above 80°C. During warm days or prints on
an enclosed machine, the stock stepper motor surface temperature will
hover between 70°C and 75°C for long print durations at moderate
extrusion speeds.
Unless you are using a pancake stepper, your stepper motor shouldn’t
overheat, so make sure you check you are within your Vref range. The way
to test for this is explained in both the “Extruder Motor Skipping” and
“Layer Shifts” chapter, in which calculating your ideal Vref and how to
tweak it are explained. Going over your rated Vref can lead to overheating.
Along with reducing the current to the stepper driver as mentioned in next
section, you can provide some external ways to cool these motors.
The extruder motor is one of the most common to overheat, so it can only
be beneficial to add a passive heat sink. Increasing extrusion rates while
maintaining a constant output temperature will require additional torque
from the extrusion motor. This additional torque will require more power,
which creates thermal dissipation through electro-mechanical inefficiencies
– meaning this motor will become hotter the faster it runs.
After the extruder motor, the X and Y steppers are second most likely to
overheat, since the Z will only move intermittently. The photo below is a
heat sink on the X-axis motor.
You can either screw a heat sink into your motor, get thermal glue, or some
use some strong thermal double sided tape to stick it right on there. These
will increase the heat dissipation of the individual motor by expanding the
area available for convective heat transfer.
I suggest to everyone that they at least put a heat sink on their extruder
motor. You can touch your extruder stepper mid print and see just how hot it
is getting.
Finally you can connect a fan that will actively blow on that stepper motor.
You can wire this fan directly to the power supply on your board so that it
turns on when your printer is on, allowing for cooling of any overheating
stepper motor. This is not needed on most machines, but if you are running
hot, this is a pretty surefire way to help remedy.

You should then also check to see if you are feeding out too much power
from your stepper drivers, which can lead to overheated stepper motors.
Stepper drivers overheating
Along with your stepper itself overheating, the stepper drivers can overheat.
Most drivers will come with very small heat sinks that definitely help, and
if yours does not, I highly recommend applying them. Though this helps, it
is not enough in itself to entirely prevent stepper drivers from overheating.

As mentioned
elsewhere in this book, you will always want 1-3 active cooling fans
blowing onto your board. This can do wonders when it comes to
overheating drivers and other parts on your board. All pre-built machines
should have these fans standard, but they can burn out or be damaged over
time. If you are building your own machine, you need to include these fans.
Just remember that if you do not have a filter on these fans you will see dust
accumulate which can cause the fans to fail over time. Always make sure
your printer is off when it is not being used to not collect unnecessary dust,
and to clean these fans and your board periodically. Almost every pre-built
printer comes with these fans on the board standard, so periodically check
to make sure this is spinning well.
If still experiencing overheating, you will want to check that the current
going to that driver isn’t over the rated limit via the methods described in
the “Extruder Motor Skipping” chapter, or in the “Layer Shifts” chapter.
These stepper drivers are inexpensive, so if you are continuing to have a
driver overheat, it might be smart to try and replace it. Just be careful – an
overheated stepper driver will be so hot to the touch it can hurt you.

Unlevelled X carriage
In the “Unlevelled Build Plate” chapter in this book I mention that it is
important to level the right and left side of your X carriage in relation to
how close it is to the build plate. These can become unlevelled over time,
but you will see some massive differences if one Z stepper driver is
malfunctioning.
If you notice your printer is looking like the photo above, you likely have a
malfunctioning stepper (or stepper driver) for the Z-axis motor(s). It could
also mean one of the parts on your frame is broken, so inspect closely.
This, as well as any other stepper malfunctioning, will have to be remedied
as follows:
Plug in a different stepper motor (or plug
the current stepper motor into a different
driver)
You can test to see if it is your stepper or driver/board that is malfunctioning
by swapping the stepper motors. Unplug the stepper in question and take
those same wires and plug them into a different stepper you know is
working properly (either on your machine or a spare that you have on
hand). Attempt to move the stepper again by moving the axis in question
and see if it is working properly. If it is, this means you will have to replace
the motor that was malfunctioning.
If when you plug in this different stepper that you know is working, and it
does not spin when moving the axis in question, you have a problem with
either your stepper driver or your board. This is assuming you have
confirmed that all wires in question have continuity (as described above).
You can achieve this same outcome by using the motor in question but
plugging it into a different driver that you know is working.
Replace a motor if it is the problem, and move on to the next step if it is
working fine.

Check the continuity and wiring of the

stepper in question
With the frequent rattling and movement of your machine, wires can easily
get caught mid print and become either disconnected or frayed to the point
they are not providing continuity. The first thing you will want to do when
you see a stepper is malfunctioning is to check the continuity of each wire.
If not visually frayed, you will need to take your multimeter and switch it to
the continuity tab. Turn off and unplug your machine. Then unplug the
connector for the stepper in question and its connector to the board.
 Take either lead
and touch it to one of your wires inside the connector to your motor (be sure
it is touching metal). Take the other lead and repeat the process for the
connector that is going to the board for the same color wire you are testing
on the motor side.
If you hear a beep, that means there is no break in that wire – there is
continuity from the starting point of the wire to where it connects to the
motor.
Continue the same process for each colored wire. If you notice that one of
the wires is not beeping, that means there is a break in the wire somewhere.
Follow that cord from the motor to the board and see if there is anything
you can see with the naked eye (frayed, cut, or burnt out sections of the
wire). If it easy to spot, cut that section, re-solder, and confirm that there is
continuity.
If there is no physical damage you can spot with your naked eye, you will
want to replace that wire entirely. Once you confirm all wires have
continuity from the board to your motor, everything should be working
properly again. If not, move on to the next step.
Test your stepper driver by swapping it
Once you have confirmed that your wires all have continuity and that the
stepper motor itself is working, you will want to test the stepper driver in
question. This is simple and can be done with any spare stepper driver you
may have, or by just testing a driver for a different motor you know is
working.
Unplug the driver in question and plug your spare/new driver in. If
everything works just fine, you know it was the driver that was
malfunctioning. Always make sure you are using the proper stepper motor
for your machine setup.
You will want to make sure that this new stepper driver doesn’t overheat
and get burnt out again. If you are using a different brand driver, you may
need to figure out the proper Vref (as explained in the “Layer Shifts”
chapter). If you have the proper fans blowing, and your new stepper driver
over heats as well, you may unfortunately need a new board.
Final fix - replace your board
Finally – if all wires are showing continuity, the motor is proven to be
working fine, the stepper driver is functioning just fine - it’s likely that you
unfortunately have a malfunctioning board. Ramps boards are very
inexpensive but some printers other boards such as a Rambo that may cost
close to $150.
Once you have made it this far in your testing, and you made sure you are
using all the proper parts, I can almost guarantee the issue remains in the
board itself. Boards that require NANO fuses will not work at all if the
NANO fuse is blown, so if you are able to heat your extruder and move
different axis’s, then it is not a NANO fuse problem.
Buy a replacement board, or get a free replacement if under warranty, and
embark in the annoying process involved in unplugging and re-plugging
everything (with your printer off and unplugged of course). Some machines
can be extra frustrating to do this on because of the limited space you have.
You unfortunately will not be able to just test the one motor in question
until everything is wired and your board is flashed with the appropriate
firmware.
I suggest you take a picture of your old board while wired so you can refer
to it if you get lost connecting your new board.
Once everything is plugged in, and the correct firmware is flashed, test
everything out. If all the proper tests above were taken, everything should
now be working fine.
Remember to test all wires and motors before going this final route, since
you don’t want to spend your time and money only to have the issue occur
again with the new board.
Summary of Fixes and Precautions
If motor is extremely hot to the touch during a print, add a heat sink.
It is smart to add a heat sink to your extruder stepper regardless.
If motor is still overheating, add an active cooling fan.
If overheating is an issue that a heat sink or fan cannot overcome,
check the Vref of the stepper driver and make sure it isn’t over your
rated amount.
Add a heat sink and active cooling fan to an overheating stepper
driver.
Check current on stepper driver if still overheating.
If motor is malfunctioning regardless of heat, check continuity of all
wires from it to the board.
Replace or fix all wires that do not show any continuity.
Test a different motor or plug a different driver’s cords into the
stepper in question to test if the stepper itself is the culprit.
If stepper itself is not working, replace it.
If stepper is functioning, check the driver by testing a spare.
If driver itself is not working, replace it.
If all above fails, purchase and install a new board.
Stripped Filament
If you are noticing that your filament is stripping during the print, it may
result in a part that look under extruded. This is because the shaved filament
will not be fed through the extruder.
Constant filament stripping without any cleaning being done can lead to
your extruder slipping, due to the teeth on your hobbed gear/bolt becoming
less sharp as filament wedges itself in between the grooves. All of this will
cause further under extrusion and failed prints.
Moisture in your material
The number one reason this problem will consistently occur is due to the
material having absorbed too much moisture. When this first happened to
me I did all of the steps below, but no matter what I did, the particular spool
of PLA would just grind until it could no longer print. This was on a direct
drive Titan extruder that I had checked multiple times for any problems.
Well, I eventually put a different spool of PLA on and it printed great. It
ends up that the spool of PLA had absorbed too much moisture and could
not print properly. You can notice this if you see bubbling when extruding,
but another is if the material continually grinds down.
All filaments require you to store them in a low humidity area – either via
vacuum sealing with desiccants, or being left with a dehumidifier set to
around 25% (or just as low as it will go). You should make note of where
you live, since this won’t be nearly as much of a problem for those living in
the desert, versus myself living in a more humid climate.
When writing the first two editions of my book I lived in Southern
California where the humidity never rose very high, which meant I could be
more lax with my handling of filament. Now that I live in Texas where the
humidity is always higher, I need to vacuum seal every material when it’s
not in use.

If your filament
keeps getting grinded until it looks like the photo above, you will either
need to replace the spool, or get it dried out.
You can purge out the excess moisture a couple of ways – the best doing a
minor vacuum purge after heating to a bit under the materials glass
transition temperature. You can use your printer bed to place the vacuum on
stop of as a means of heating everything.
Most of us do not have a vacuum, so here are the steps for what you can do
with the tools you have at home.
First – check the glass transition temperature of the particular material you
are using. PLA is right around 60 degrees Celsius, so you don’t want to get
it hotter than that. Turn your print bed to this 60 degrees (or slightly lower),
and then place the spool of filament on the print bed. Cover it with a
cardboard box (you can use the one it was shipped in). Make sure to throw
in a couple of desiccants that have not been used. Leave it there for roughly
1 hour. The heat will help to evaporate the moisture from the spool, the
desiccants will help absorb, and the cardboard box will help trap the heat
while doing a minor amount of absorbing as well.
It took me 3 rounds (3 hours) of this and it fixed my moisture filled spool of
PLA perfectly. I was able to print as if the spool was brand new without any
grinding filament.
This may not always work, so you want to make sure to use the proper
precautions to avoid ever having to do this. Nylons are much more likely to
absorb moisture, and thus would be a bit more difficult to complete this
process.
In fact, most materials just have a shelf life. Nylon material may only be
good for a month or two even if you take the proper precautions. Even a
year old PLA will just not be as good as it was when it was first delivered to
you. Keep this in mind before you tear your hair out trying to fix a spool
that you’ve owned and has been open for a year.

Clean your extruder

As I mention in the “Good Practices” chapter early in this book, keeping
your parts clean is important to have consistent prints without failure. This
definitely includes your extruder.
If you are experiencing stripped filament, or would like to prevent it as best
you can, grab a small wire brush and pick and clean out the teeth on your
hobbed bolt/gear.
If these grooves are not defined, they will not grip properly to your
filament. This can lead to filament slipping and stripping.
Check idler tension

As mentioned for
other issues in this book, you will want to make sure you have the proper
tension on your extruder idler. Too tight of an idler can cause the extruder
motor to skip if under powered, and to even cause filament grinding to the
point of snapping when it is geared.
While grinded filament can occur from too tight of an idler, it can actually
also occur from an idler that is too loose. This is because no consistent grip
is attained by your hobbed bolt/gear, and certain rotations will just rub
against the filament, rather than pushing it through your hotend.
It is important to get this tension right since it can cause various issues in
the quality and consistency of your prints.
Increase hotend temperature
I always recommend this with caution because if you go too hot, materials
will easily get clogged in the barrel, causing you the need to read the
“Nozzle Clogs” chapter in this book. But as mentioned in that chapter,
running the hotend too cold for the speed you are feeding can lead to under
extrusion.
In fact, it is smart to read the “Nozzle Clogs” section now if you haven’t
already. That is because a nozzle clog will certainly lead to stripped
filament, meaning if you fix the nozzle clog, you may fix the stripped
filament problem.
Your extruder stepper may be turning the proper amount of steps, but
bottlenecking in the nozzle will cause your hobbed bolt/gear to just rub
against the filament when the pressure is too high.
If you are under the high end of the temperature range for your material,
you can attempt printing the same G-code at a slightly higher nozzle
temperature in order to help the viscosity of the material.
Don’t go over the materials temperature range, since running PLA at 230°C
can give you further problems with clogging in the barrel and oxidizing
material.
Lower the speed/acceleration
Just like with the solution described above, lowering the speed and
acceleration can reduce the amount of bottlenecking caused in the
hotend/nozzle.
You can imagine that if you were to speed your extruder up 10 fold you will
clearly grind your filament, since it cannot be fed through your nozzle at
that speed since it cannot properly heat the filament (which is one of the
benefits of a hotend like the E3D Volcano or Super Volcano).
You do want to make sure you have a properly cooled barrel and that you
understand what material you are using in order to reduce the threat of heat
creep. Certain materials have a very small range of temperature and speed
they can properly be extruded at without a clog being formed.
If you would like a tutorial on how to reduce the acceleration on your
machine, please refer to the “Extruder Stepper Skipping” or “Settings
Issues” chapter in this book
Printing fast on large diameter nozzles
You will need to slow down prints when attempting to print large layer lines
on a large diameter nozzle with a standard setup. This is because the
material needs a certain amount of time to heat and reach its proper
viscosity to extrude. Since you are pushing so much material through the
nozzle, it needs to be slowed down to prevent filament grinding.
If you will be printing on large diameter nozzles (Larger than 0.6mm)
frequently, it is smart to upgrade to a hotend setup that is specifically
designed to allow for high volume extrusion. E3D has their Volcano setup
which is meant for just this purpose – printing fast with large diameter
nozzles and layer heights. You will clearly need a geared extruder to even
achieve these speeds, which is why they also sell their Titan extruder. You
can use the Bondtech BMG in conjunction with a Super Volcano hotend for
the fastest printing possible.
Replace hobbed bolt/gear
Please keep in mind that cheaply made hobbed gear and bolts may not have
the proper spacing, sharpness, and depth required to grab onto the filament.
These components also wear over time, particularly if you are running
carbon or glass filled materials. If you are experiencing constant filament
grinding regardless of the steps you took above or the material you are
using, you should purchase a new extruder hobbed bolt/gear from a
reputable manufacturer. Choose stainless steel options over aluminum for
this part, if available.

I currently use
the Bondtech BMG extruder which actually has two gears grabbing onto the
filament, rather than just one pushing against a bearing. This dual drive
extruder has made it so that I haven’t had any grinding or extrusion issues at
all since purchasing it over a year ago. I cannot recommend this extruder
enough, though it does currently come with a hefty price tag ($100 at
MatterHackers.com).

Summary of Fixes and Precautions

Confirm the material you are using hasn’t absorbed too much
moisture. This is the most common reason for this.
Replace filament, or dry out your material if it has absorbed
moisture.
Clean your extruder by making sure there is no filament stuck in the
teeth of your extruder’s hobbed bolt/gear on your extruder.
Check to make sure you have the proper tension on your extruder
idler.
If you are below the maximum suggested printing temperature for
your filament, try increasing it slightly.
Reduce the speed and acceleration on your print. Make sure your
barrel is properly cooled.
Replace poorly made or worn-out extruder hobbed bolts and gears.
Unlevelled Build Plate
An unlevelled build plate will mean that the nozzle is too close in some
areas and too far away in others. If the bed is extremely unlevelled, there
may be structural issues with the way the build plate is mounted to the
frame, however, in most cases it is minor (less than an mm height difference
from one corner to another). In these situations you just need fine tune
adjustments to the spring loaded corner mounts of the build platform.
Many new FDM 3D printers come with an auto bed leveling system that
actually works, and there are some third party bed levelling sensors that are
useful, unlike attempts in the past. I go over these a bit further in the
“Upgrades and Purchasing a New Printer” chapter, as well as a later section
in this chapter.
The majority of my machines now have these auto bed levelers, since I find
them worth the price when it comes to this annoying issue.
You can easily diagnose this problem by either running a bed calibration G-
code, or by paying close attention to the first layer of your print. By getting
used to what a print should look like on its first layer, you will easily be
able to which corners are too close, and which are too far.

(Remember that
you can email me at [email protected] with proof of purchase for
high def photos and color PDF files)
The photo above is easy to diagnose this – the front left corner has the
nozzle too far from the build plate and the top right corner is way too close.
Somewhere in the middle the nozzle is the proper distance.
An unlevelled build plate, along with Z-height calibration, are the two most
common failures when starting a new print. Most printers either have bed
clips or some form of mechanical leveling system. These screws become
loose over time, and even one long print can cause your bed to become
unlevelled for the next run.
If you continue to only tighten corners without adjusting your entire bed, it
can result in a warped metal build plate, and eventually constant layer shifts
- as mentioned in that chapter in this book.
Levelling left and right side before
touching corner bed clips
Before you even bother adjusting the corner bed clips, you will want to
level the left and right part of your X-carriage. Variations over time, moving
your printer, as well as times that you home the Z axis too close to the bed,
can all cause your two Z- rods to become unleveled from each other in
relation to the X carriage.
Mind you that this issue should only be relevant to Cartesian machines.
CoreXY and Delta should not have to worry about this.
If this is just a maintenance problem, and not an issue with your stepper
motor (as mentioned in the “Steppers Motors Overheating or
Malfunctioning” chapter), you can level this while your steppers are
disengaged. Hold onto the left coupler that attaches the left threaded Z rod
to its respective stepper motor. While holding onto the left coupler, twist the
right threaded Z rod’s coupler in the correct direction to level your X
carriage. This is obviously only true when using dual Z leadscrews/threaded
rods.

You can measure

the distance from the bed to the X carriage rod on the right and left side of
the build plate, and continue the above process until they are even. If you
attempt to just tighten bed corers while your actual frame is off, it will result
in further issues.
Loosen/tighten corner bed clips
If you have confirmed that the left and right side of your X carriage are
level to each other in relation to the build plate, and you are still
experiencing an uneven first layer, you will want to play around with the
corner bed knobs of your printer.
I always suggest that you loosen before you start tightening these corners.
That means you should try to loosen the corners that are further from the
nozzle rather than tighten those that are too close. So if one corner is too
close to the nozzle, I would suggest raising the z-height slightly and
loosening the remaining 3 corners until level. This is because you do not
want to be in the situation where you cannot tighten a corner any further.
This leads to a warped metal plate overtime and will cause layer shifts in
the Y-direction since it becomes rough to move. This is not nearly as much
of a problem on CoreXY machines since the build plate only moves down
in the Z-direction.
This is not always possible though, because you can imagine the above
situation where 1-3 corners are too close to the nozzle and the remaining
corner(s) are as loose as they can go. You can always use a longer screw
and larger spring on those corners, but if that is not feasible, you will want
to tighten those corners that are too close to the nozzle.
On newly built, or strong framed machines, this can be as simple as doing a
slight tweak while a new print begins. Printers that have a lot of build time
racked up can lead you to having a massive headache going forward with
the above method. If you are unable to level the build plate easily with the
above two methods, I sincerely suggest entirely starting over. If you just
over tighten, the build plate will move with a lot of resistance, which is not
good for your printer and parts.
This means that you should take your build plate apart, make sure
everything is assembled properly, and put it back together. Make sure that
all corners have the same length screws and same exact springs and are all
equally tight. Then confirm once again that the left and right side of your X
carriage are level. Find the proper Z-height and then run a bed leveling G-
code that you can easily find online if not provided by your printer (just
search on Thingiverse for a bed level test). Starting from scratch like this
can often make this issue go away.
If you still cannot level your build plate after all of this, you likely have an
issue with the frame of your printer. Take the metal bed plate entirely off
and lay it on a flat surface. You can then push on each corner to see if it has
warped. If this is the case, you will need to order a new metal plate from
your printer manufacturer.
If the plate is flat, confirm that your frame is built properly. This means that
if you are using t-slotted aluminum rods, confirm that everything matches
up in a 90° angle and that it lays flat on the tabletop you are using. Some
printers have little feet that make sure your printer lays flat but they break
off easily.
Confirm that all printed parts on your frame are not warped. Check to see
that all bearings are popped into their holders and that everything is equal
distance from each other. It would be smart to go over the “Mandatory
Maintenance” chapter to make sure everything is working as it should.
If you are using an acrylic framed printer this problem will become more
prevalent over time. All metal framed printers experience less warping and
bending over time.
One or multiple corners of your build plate may not be laying perfectly flat
because of the issues above.
Larger layer heights/nozzle diameter can
make this process easier
If you are using a 0.25mm or smaller nozzle with 0.1mm layer heights or
lower, you will notice extremely slight variations in how level your build
plate is. As mentioned in the “Z-Height Calibration” chapter, the lower the
layer height and nozzle diameter, the more difficult it is to get your first
layer to stick to the build plate.
On any print like this I would suggest increasing the initial layer height on
your slicing program. Increase the first layer to be 0.2mm and you will have
a much easier time leveling the build plate. The same is true if you are using
a very small nozzle.
0.4mm nozzles can get most jobs done and will allow you to get that bed
adhesion that is so hard to come by on 0.15mm – 0.3mm nozzles. On a
0.4mm nozzle I have 0.25mm or 0.3mm layer heights for the first layer,
which can save you an immense amount of headaches.
A build plate on a printer using a 0.6mm nozzle with a 0.3mm initial layer
height will be relatively extremely easy to level when compared to a
0.15mm nozzle with 0.05mm layer heights. On these small nozzles, always
max out the initial layer height by multiplying the nozzle diameter by 0.75.
You will still be limited to only 0.11mm for a 0.15mm nozzle, but it will at
least be easier than going lower than that.
Please refer to the “Settings Issues” chapter for a further explanation.
Do not frequently move your printer
FDM 3D printers are not meant to be travel ready and should stay in one
spot as much as possible. Every time you move your printer, especially
when traveling in a car, minor adjustments can occur that will require you
to recalibrate.
The most common issue with moving your printer is having to readjust an
unlevelled build plate. When we would take printers to fairs and events in
the past, we would ALWAYS have to re-level the bed when setting up. Take
care not to bump into, move, or vibrate a printer, even when it is not in use.
Purchase an auto bed leveler
You can purchase a part that will allow you to auto bed level your machine.
You will still need to get the proper Z-height, but your printer makes minor
movements in the Z-motors to make sure the bed is level.

I personally upgraded my CR-10 to use TH3D’s EZABL which will take a

reading of the bed before printing to make sure that first layer is perfectly
level. This part takes 9 points on the bed in order to get a mesh, though you
can change this number to be more or less precise. After honing in the Z-off
set, it then uses the Z-motor (or motors) to vary the height of the print as the
nozzle moves. This means if one corner is too far from the nozzle when
compared to another, the z-motors will tweak to make sure the nozzle is
closer in that section.
This minor motor movement can be seen when looking closely at the first
layer. I am extremely happy after upgrading to this since I no longer have to
deal with this particular failure on this machine. I still have to make sure the
Z-height is correct, but no more messing with individual corner knobs. And
I promise you – an unlevelled build plate caused me far more frustrations in
the past than I would like to admit.
Summary of Fixes and Precautions
Confirm the left and right side of your build plate are equally level
to the X-carriage. This is only needed on Cartesian machines.
If they are not, while stepper motors are disengaged, hold onto the
left threaded Z-rod’s coupler and twist the right threaded Z-rod’s
coupler until level.
Loosen the bed corner knobs that are too far from the nozzle relative
to the remaining corners. Tighten only when needed.
Start from scratch by dissembling build plate and making sure all
corners are equally tightened, using same sized screws and springs
with equal amount of tension.
If still experiencing issues, confirm that your metal build plate is not
warped, the printed parts on your machine are not warped, and that
the frame is put together properly.
If any part is warped or off tolerance, you will need to purchase or
print replacements.
Increase your initial layer height, or even increase the diameter of
your nozzle if you don’t want to deal with this issue as frequently. A
large initial layer height makes leveling the bed much simpler.
Take care not bump into, move, or vibrate a printer - even when it is
not in use.
Upgrade to an auto bed leveler to prevent this problem from
happening.
Warping
The warping of parts is just about inevitable if you don’t understand the
material or machine you are using. Warping is when corners, or entire parts
of the print curl upward due to uneven cooling of your part, or due to
improper bed adhesion.
Both the first and second edition of this book were written before my
collaboration with Nicolas of Polymaker and his “Material Science” chapter
contribution, and because of this, I never fully understood why warping was
occurring. Ever since working with them, it has helped my understanding
immensely. I can’t suggest enough that everyone checks that chapter out so
that you know why warping is occurring – since it may help you to
diagnose and fix the problem without reading on.
Understand the “Bed Adhesion” chapter,
“Z- Height Calibration” chapter, and the
“Unlevelled Build Plate” chapter
You need to entirely understand all three of these chapters in order to even
start to try and fix your warping problems. A print will have an
exponentially higher chance of warping when either part of the print, or the
entirety of the print, is too far from the build plate.
This is fairly easy to understand because the further the nozzle, the less bed
adhesion that is involved, the higher chance it will curl up later in the print.
You will need a brim on any material that has a high shrinkage rate and high
internal stress rate such as ABS. For large non-circular ABS prints, you will
need an ABS slurry if you cannot maintain an ambient air temperature of
around 45°C – all things covered in those three chapters.
Understand the material you are using,
and possibly use an alternative
Much of this is covered in the “Material and their Settings” chapter, so
please review this as well when understanding your material needs.
You will almost never experience issues with warping when using a
material such as PLA, because PLA has a low shrinkage rate and low
internal stress of the material (though, to understand this better, refer to the
“Material Science” chapter). Very large, highly dense PLA parts should use
a heated build plate and a brim, but it is very uncommon to get warping
with PLA on a level build plate.
ABS is an entirely different matter, being an amorphous thermal plastic
with a lot of internal stress when extruding. Since ABS also requires a
higher temperature for its build plate due to its higher glass transition
temperature, the differential between the bed and the ambient air is also
increased.
While ABS is great for its price and functionality, this factor may make it
impossible for you to achieve certain parts on your machine without
warping. This is why it is important to understand the factors and features
you are looking for on your print and if you can use an alternative material.
If you require mechanical functionality and affordability, but do not care
about acetone vapor finishing or a high glass transition temperature, you
should definitely try out PETG. PETG is a great material for the vast
majority of mechanical applications you were attempting to get out ABS,
and has a very low relative warping chance. It also has a competitive price
tag.
PETG has some serious adhesion when a bed is set to 70°C, and I have yet
to experience major warping on a level build plate when using this material,
though it is definitely possible.
If you require a high glass transition temperature from your material, I
haven’t personally found a great alternative to ABS. One of your best
options would be Carbon Fiber Reinforced ABS by 3DX Tech. This
material has a great glass transition temperature of 90°C and warps far less
than standard ABS, while maintaining its ability to be acetone vapor
finished. The biggest drawbacks to this material is the price compared to
ABS, increased degradation of your nozzle, lower layer adhesion, and a
lower bend to break ratio. The problem with most materials that have a high
glass transition temperature is their likelihood to warp.
Certain nylon materials that do not have a high glass transition temperature
will still have a high probability of warping. This is because they are semi-
crystalline that take up less space when they are aligned (room temperature)
than when they are chaotic (extruded). It is essentially crystalizing on your
printer bed, and causing warping. More information on this can also be
found in the “Material Science” chapter. For these nylon materials you will
need to use a coat of PVA on a glass build plate, as described in the “Bed
Adhesion” chapter. Polymaker has helped with this nature of Nylon with
their PolyMide CoPA, which is advertised as “Warp Free”. It still has the
potential to warp, but compared other nylons, its far better.
I have attempted to print Polypropylene and Acetal (Delrin) in the past, to
essentially no avail. Along with requiring a high temp hotend,
Polypropylene warped on just about every print larger than a cubic inch,
and Acetal was impossible to get any print started without using a sheet of
cardboard on top of the build plate. They just do not want to stick to
standard build platforms. Polymaker is currently working on a warp-free
version of Polypropylene, so if you absolutely need that material for your
3D print, I would suggest checking to see if that is available.
Polycarbonate ABS has an amazing glass transition temperature of around
120°C but will require an enclosed environment on any print larger than a
cubic inch. This material’s warping probability is just too difficult to
overcome on most machines.
Using an ABS slurry, as described in the “Bed Adhesion” chapter, can help
with particular ABS blends to truly stick to the build plate.
Print slower and increase printing
temperature
This may not work for all materials, but for ABS you can help to reduce
your warping issues by extruding slower and at a higher temperature. As
Nicolas of Polymaker covers in his chapter, printing slower gives the
material more time to release its stress. This means that a lower extrusion
speed will reduce your warping problems.
The same is true with the extrusion temperature. Increasing the extrusion
temperature means more motion within the material. More motion + time to
release stress = less warping. Printing ABS as slow as possible on your
machine, along with printing temperatures up to around 250°C, can help to
reduce these internal stresses, and thus, reduce warping.
Printing in an enclosed environment
When you are printing a part on a heated build plate you are automatically
working in an environment with uneven ambient temperatures. When the
room is around 30°C and your heated build plate is 110°C, there is a quick
change in temperature for parts close to the build plate, yet exposed to the
surrounding air. While internal stresses may be the biggest reason for your
warping, this extreme temperature difference will also cause warping
problems.
Printing in an enclosed machine allows for the ambient air to remain a bit
hotter, due to the trapping of the heat given off by the build plate. This
means you are closer to the glass transition temperature of ABS, allowing
for more motion in the material and are giving it more time to release stress.
You can purchase a printer that is enclosed, or somewhat enclosed, which
works pretty great if you can afford them. You can also build a DIY
enclosure with laser cut acrylic and a few printed parts. Or you can find
some other build that someone has posted instructions for online.
When printing a part with a high likelihood of warping in an enclosed
machine, you will want to let the bed sit at its printing temperature for
around 5-10 minutes to allow the ambient air to heat up. A good ambient
temperature for ABS would be 45°C, and ideal up to 60°C. You obviously
would not want to print PLA in that type of environment though, since that
is right around its glass transition temperature.
Many issues arise when you allow ambient air to rise this high. Stepper
motors and other electronics will overheat and cause your printer to
malfunction. This is why you will need to have your power supply and
board outside the enclosed chamber, have enough heat sinks spread
throughout, and keep an active fan on anything that is heating too hot. E3D
actually has a water cooled option now, but it is not very common. Read up
on the “Stepper Motors Overheating or Malfunction” chapter as well.
Even then you may still experience issues, so be sure to understand some
basic thermal dynamics and mechanical engineering before getting your
ambient air to 50°C or higher.
To be honest – this isn’t quite as important as it may have been. Due to
there being so many material varieties, and from your now understanding of
material sciences, you can likely avoid most warping problems even on an
open printer.
Delamination of layers
You may not consider this failure as “warping”, but it has nearly all of the
same reasons for happening. This is why it is not included in the “Poor
Layer Adhesion” chapter.

If you have
incredible bed adhesion, such as when you use an ABS slurry, but are
printing a large part in an open environment, you can experience
delamination instead of warping.
Delamination is when two layer will separate from one another, even when
taking in all the layer adhesion precautions. This is because of the same
temperature gradients and internal stresses explained earlier, but occurs
when bottom layers are stuck extremely well to the build plate.
The bottom of your print may not curl upward taking the entire print with it,
but rather layer adhesion becomes the breaking point for this
shrinkage/internal stresses.
If this is happening to you, you will need to check your settings or
drastically change your environment/material being used.
I have only experienced delamination on very large PLA prints when the
ambient air is quite cold, while it can be unavoidable on tall ABS prints not
in an enclosed environment.
Your settings can be tweaked to help prevent this. The denser your part is
on the inside, the more likely this will happen, so try printing your part with
less infill and a couple more shell walls. Print slower and hotter to also help
slow down the material releasing stresses and have more motion.
Finally, confirm that your E-steps are on (as explained in the “Over and
Under Extrusion” chapter). If you are under extruding by a decent amount,
you could potentially experience more frequent occurrences of
delamination.
Make sure the build plate is not losing heat
mid print
If your board is overheating or you having issues with connectivity to your
heated build plate, the temperature may drop mid print. If you only watch
the beginning of your print and come back when it is finished, you may not
even notice this is happening other than returning to a warped part.
Make sure your bed is maintaining its heat throughout the entire print, and
if it is not, refer to the “Build Plate Not Heating” chapter

Summary of Fixes and Precautions

Read the “Material Sciences” chapter in this book before reading
this chapter. It will help you to understand why warping is actually
occurring.
Make sure your bed is level and that your Z-height is correct when
starting your print.
Use your preferred method of bed adhesion. Some large ABS prints
on a non-enclosed printer will require an ABS Slurry.
Print slow and hot to give the material more time to release stress
and increase the motion within the material.
Print with a brim.
Know the proper print settings for the material you are using.
Attempt using a material with a lower shrinkage rate and internal
stresses with similar applications (PETG, CFR-ABS, PolyMide
CoPA, etc.).
Use an enclosed 3D printer, or build an enclosure for your machine,
but understand the possibility of parts overheating.
Delamination occurs on taller parts that have good bed adhesion.
You will need to reduce the density of your part, print an enclosed
environment, or use a different material in order to fix this problem.
Make sure the build plate is maintaining its temperature throughout
the print.
Z- Axis Wobble
When you are experiencing Z-axis wobble, you will see what looks like
repeated minor layer shifts, sometimes with every single layer. If the
wobble is minor, it may just look like the print surface is not clean. You can
hone in all of the slicer settings properly, but it will not fix this issue. This is
an issue with the frame of your printer and not an issue with settings.
 Tighten
extruder carriage and hotend setup
This is probably the most common cause for a wobbly looking print. Your
extruder carriage is moving and rattling constantly over prints and screws
loosen over time. This is especially common on 3D printed parts, since their
tolerances are not as tight as mass produced carriages and extruders. This
will be far less of an issue if using an E3D Titan extruder with an E3D
hotend on a $3,000+ machine than on a $200 stock Prusa i3 with printed
parts.
This is because more expensive machines usually have higher end parts
holding everything together. Lower end machines will use printed parts
with minor tolerance issues, and may even use zip ties to hold belts and
bearings in place. These zip ties can become stretched over time and results
in a carriage that is not harnessed tight.
Frequently check to see if you can easily move or rattle your
hotend/extruder setup. Lower the print temperature to room temperature and
literally grab the hotend and try and move it around. Don’t be rough, just
give it a little rattle. If you see the carriage or hotend rattle or have free play,
you will need to fix that in order to get rid of this problem. The machines
that I have used that have this setup be extremely stiff result in the least
amount of Z-wobble.
If you can, you will likely need to tighten the screws/bolts that hold the
extruder or hotend to the carriage. If tightening doesn’t fix the problem,
check to see if your printed parts are worn out or off tolerance. If they are,
you will need to reprint them. If not, you can move on to the next solution
Replace old/worn out bearings and make
sure they are harnessed tight
If your carriage is rattling when you manually try to move it, but your entire
extruder carriage and hotend are tightly set up, your bearings may have
become loose over time. This is far more common with plastic bearings
than with metal ones, as you can imagine.
This is for linear rods, not for linear rails. Linear rails do not use bearings to
hold onto and slide the carriages, they use rollers. They normally result in a
stiffer frame, which is why many people prefer linear rails on their
machines.
When doing the step above – rattling the hotend when at room temperature
on a machine with linear rods– you should be able to see if there is a small
gap in the bearing.
I didn’t think this could happen until I replaced a 2 year old printer’s
bearings who was experiencing consistent Z-axis wobble, and it fixed the
issue instantaneously. These were on Lulzbot TAZ 5 machines that used
plastic bearings. The replacement bearings had no free play and gripped the
linear rods tight.
If you are using a less expensive machine that uses zip ties or something
similar to hold the bearings in place, you will need to replace these with
new zip ties, or find a part online to print that will hold the bearings tight. I
have come to prefer linear rails as of late just to reduce this ever becoming
an issue.
Ensure your hotend and nozzle is set up
properly and tight
This process is explored in the “Built up Material in Nozzle” chapter, but
can also show symptoms in a Z-axis wobble. Every hotend setup needs to
be assembled in a slightly different fashion, but nearly all of them require
you to not over tighten. This can lead to you leaving them too loose.
When the hotend heats, the metal expands and can cause your once tight
nozzle/heater block to actually have minor gaps. This can lead to rattling of
the heater block throughout the print, causing an ugly wobble in your print.
If you notice that your heater block is loose when hot, or that you constantly
have to brush off the nozzle from excess material, you will likely need to
tighten these parts.
I always suggest doing the final tightening of your nozzle and heater block
when heated to 240°C, using proper gloves and tools. Remember that you
have a high chance of burning yourself, so only do this with extreme
caution. If you tighten the hotend/nozzle when at room temperature, you
will find it won’t be tight at 240°C.
You still want to make sure to not over tighten anything. I have broken quite
a few heater blocks, nozzles, and heat break barrels due to over tightening.
These parts, especially when hot, can easily snap under pressure. This
hasn’t happened to me in a while, but would occur when I didn’t understand
how careful I should be. When you are doing this, make sure to only tighten
until you know that the nozzle and heat block are not loose and will not
unscrew during the print – don’t muscle it. Just make sure you do this when
hot.
If you still are experiencing your hotend is rattling and you have made sure
it’s harness is tight, you will likely need to upgrade or replace your nozzle,
heat block, or entire hotend. Poorly made parts will not have tight
tolerances and can lead to these gaps in your threads. You can try to save
money if you want, but I only purchase from reputable manufacturers for
this reason. All of my hotends are from E3D, since they are one of the most
respected companies in the 3D printing field.
Make sure the build plate is harnessed
tight
Just as with the extruder carriage and bearings, you will need to make sure
your print bed does not have any rattling in it. This will NOT be an issue
with CoreXY machines, since the bed only moves up and down.
When using a Cartesian machine, free-play or rattling in the build plate will
result in Z-wobble, just as it would with rattling in the hotend. When not
printing, and with the bed at room temperature, give it a good rattle up and
down and left and right. The print bed should not have any movement other
than what comes from the whole machine moving. If the print bed has some
free play in the bearings or harness, this will need to be fixed.
On one of my inexpensive DIY machines, the build plate harnesses are
attached to the bearings via zip-ties. These zip ties seem to stretch over
about a month or two of printing, and so I will cut them off and replace
them as needed.
Just as with the carriage, you will need to replace any plastic bearings that
have become worn out over time (unless using a linear rail system).
Finally, make sure that the parts that are connecting the bearings to the build
plate are securely tightened and up to tolerance. Take your glass or other
print surface off, and then tighten all of the screws that are connecting
everything. These, as with all other screws, will loosen over time.
Tighten all belts
Other than confirming all harnesses are tight and that there is zero rattling
on the extruder and build plate, the next most common reason for Z-wobble
is a loose belt.
As explained elsewhere in this book, it is possible to over tighten a belt, but
it is pretty difficult to do so on low end machines where the belt is just held
together via zip ties. Both the X and Y axis belts should be very springy to
the touch with zero-droop.
If there is any droop in your belt, you will need to tighten. For low end,
non-upgraded machines, cut the zip tie that is holding the belt together, grab
some pliers, and pull tight as you put on a new zip tie. Make sure the belt is
tighter than it was and that the zip tie is pinching everything so that the belt
won’t slip.

Even better than

doing this would be to print a manual way to tighten your belts. There is
likely a file on Thingiverse for your specific machine setup, you would just
need to search. I have added such a way to tighten the X-axis belt on my
CR-10 by a model designed by donnyb99 on that site. I disassembled the X-
axis belt and where the bearing is connected, and then added this printed
part. I can now easily tighten the X-axis belt via a simple turn on the knob.
Be careful when adding one of these, since you will now be able to over
tighten, which I had mentioned is difficult to do without this. Just turn the
knob until the belt is very springy to the touch. There is no real scientific
way to do this, you just want to make sure there is zero droop whatsoever.
Check for wobbly or bent rods
Using thin threaded M5 or M6 Z-rods instead of thicker M8 or M10
leadscrews will lead to a wobbly or bent rod over time. It is a major upgrade
when you have a thick M10 leadscrew that is connected on the top and
bottom of the frame of your printer, since you will experience far less z-
wobble on a machine that will last over a longer period of time.
If you have these thinner threaded rods, just move your printer up and down
in the Z-axis. You will actually be able to see this problem easily since the
rods will wobble back and forth. This is exactly what happened on my DIY
machine and I fixed it by upgrading to M8 leadscrews (just make sure you
print all the parts you need before disassembling and upgrading). To get a
full tutorial on this, please see my YouTube video titled “Upgrading your
3D Printer to 8mm Leadscrews”. Almost all high end machines will use
these thicker leadscrews.
There are some models on Thingiverse and elsewhere that help with this
wobble in your threaded Z-axis rods, such as the “anti-wobble coupling” by
toolson, and they actually work quite well. While this is true, they won’t be
able to fix an actual bent rod and nothing will be quite as good as actually
upgrading to thicker leadscrews.
This is not common at all unless you frequently transport your machine. An
actual bend in your threaded Z-axis rod will require you to replace it. I have
only had to do this on one machine, one time in my history of printing, and
it was on a thin threaded Z-rod.
While I have only had one fully bent rod, I have had plenty of ones that will
wobble when moving up and down, and this is anything but ideal, leading
to minor Z-wobble.
Add an anti-backlash spring loaded nut
These are normally only meant for thicker leadscrews, and they help quite a
lot to prevent any backlash when moving up and down in the z-axis.

This is slightly
confusing as to explain, but with these springs and added nuts, you can
expect a lot less rattling and prints looking as if they have Z-wobble. Please
take note of the pitch of your leadscrew since you will need to make sure
your anti-backlash parts are the same. The majority of 8mm leadscrews
have a pitch of 2, but you will just need to confirm with your printer specs
(or with the part you buy online when upgrading).
Also make sure you are able to actually use these on the printer you are
adding them too. I bought a set that were too thick to add to the CR-10, and
their holes did not line up, having me return the set. You also want to make
sure you are able to get full use out of the Z-height on your machine. As
you can tell from the photo of my anti-backlash nuts above, I am losing
about 20mm of height on this machine since the Z-axis motors are on the
top. I have added extenders to make up for this, but keep in mind where you
add these and if you are reducing your max Z-height for prints.
These aren’t needed for most machines, but they definitely help.
Lubricate guide rods and threaded rods
Your X and Y axis guide rods should be smooth enough so that both
carriages can move around freely (when using a linear rod printer). Your Z-
axis guide rods (the ones that are not threaded) should also be smooth
enough for the carriage to move in the Z-direction without any skipping or
any bearings getting stuck.
Most printers use self-lubricating bearings, but even these will require
lubrication after frequent printing. If your bearings are getting stuck or
having trouble moving during the print, you can experience some Z-axis
wobble.

Get some white

lithium grease apply with a rag to these non-threaded guide rods. Move the
carriage around on all axis’s so that it spreads across your bearings. This
should help with the issue.
Just another reason for linear rails, since it just has rollers resting on the
rails that do not need to be lubricated.
Along with the smooth rods, you should also add a bit of lubrication to the
threaded rods/leadscrews. Just grab some lithium grease on a paper towel
and rub it up and down. You want to make sure these aren’t entirely dry to
the touch.
Make sure the bed can move back and
forth smoothly
As mentioned in the “Unlevelled Build Plate” and “Layer Shifts” chapters,
if you over tighten one or multiple corners, you will have a lot of difficulty
moving the bed back and forth (of course only on Cartesian machines). This
difficulty to move may lead to stepper motor skips which cause layer shifts,
but can also cause some Z-wobble. You will want to make sure your bed
can move back and forth easily without a ton of friction. Follow the steps in
those two chapters to help remove this problem.
Is your part too tall and skinny?
This problem will not occur quite as often on a CoreXY machine, but on
Cartesian 3D printers where the build plate is being moved back and forth, a
tall skinny print may end up wobbling. You can use as much brim as you
like with the perfect bed adhesion, if you are printing a tall and skinny part,
it will likely wobble as the bed is moved back and forth.
This wobble will make the top of your print have this Z-wobble, while the
bottom of your print looks just fine.
To be honest – there is no perfect way around this. You can manually design
some anchors onto your print so that as it gets taller, it is held further in
place, but just printing a very tall skinny part as is will likely result in this
Z-wobble.
If I am unable to design in some further anchors, I am often forced to cut
extremely thin display parts in two, to be glued together post printing.
Below is a summary of how to add a very simple anchor to your part via
Cura.
Anchoring Parts:
I am positive there are better ways to do this, but the easiest way would be
to anchor your print that I know of is in Cura. I have rarely done this, but it
definitely helps with a tall, skinny print wobbling back and forth. This is
also explained in the “Parts Being Knocked Over” chapter.
Below is an example of two skinny swords from a Deadpool print that I
made for my YouTube channel. When not adding any anchors, my
Cartesian machine would wobble the build plate back and forth and cause
the top half of these swords to look extremely ugly (if they didn’t get
knocked off entirely).
Cura now allows you to bring in a second model that intersects with your
main print. They also allow you to print a part entirely as support. This
means you can drag in a second object that acts only as support for your
main structure.

This rectangle in
the example above is thin, so that it won’t take up too much material, yet
will extend the anchoring for the sword (I added a second sword to compare
how it will slice). After bringing in a shape that will work for your model,
you can choose the model and click “Print as support”.
After turning the shape into “Print as support”, you can then drag it over
your tall, skinny print.

As you can see in

“Layer Mode”, this entire shape is now support structure that can help to
anchor your tall skinny print to help prevent this wobbling back and forth.
As mentioned – there are many other ways to do this, this is just the
simplest way since it allows you to do this right in your slicing software.
Summary of Fixes and Precautions
Tighten all of the bolts and screws that connect your extruder and
hotend to your printer.
Check to see if you need to replace printed parts on your extruder
carriage.
Reduce all rattling in the X-axis carriage.
Replace old or worn out bearings on linear rod machines.
Tighten your hotend setup while heated to 240°C, making sure to not
over tighten.
Remove all wobble in your print bed including replacing any
bearings and tightening all harnesses.
Tighten both the X and Y-axis belts. There should be zero droop.
If using a thin threaded Z-axis rod, print a part that can help guide
and reduce wobble.
If possible, upgrade to a thick M8 or M10 threaded Z- axis rod.
Replace any physically bent Z-axis rod.
Z- Height Calibration
The Z-height calibration refers to honing in how far the nozzle is from the
platform. This is determined on most machines by an adjustable screw that
will run into an endstop. This is by far the most common mistake when
starting a new print, but also the quickest to spot.
Along with many other printing failures, a combination of mechanical
issues and slicer software tweaks can be the culprit. Even when using an
auto bed leveler you will need to adjust this property.
Too close to the build plate

(Remember if
you are having trouble seeing the images to email me at
[email protected] with proof of purchase, and I will send over
high quality photos and a color PDF)
Having a nozzle start too close to the build plate can be very problematic
for your machine. Not only can it prevent material from coming out – often
causing a nozzle clog and/or extruder motor stepper skips – it can actually
damage your printer.
When a printer starts to close to the bed it will grind away attempting to
continue printing. This can cause your printer bed to be damaged by serious
scratches, and can actually degrade your nozzle. This is just another reason
it is essential to watch your first layer printing before leaving your machine
unattended.
Over dozens of prints where some started too close to the bed, you can
easily see this degradation in the picture. Yours will likely not be this bad,
but this is used to show the extreme case.

This will cause

you to have to purchase a new nozzle and possibly a new build plate. If you
are using a PEI surface, this can be an expensive fix. Never let a printer
continue if you notice it is too close to the build plate.
Too far from the build plate

If you were to let

your printer go when the nozzle is too far from the build plate, the
headaches involved can vary depending on the distance. If only slightly too
high, your part may be more susceptible to warping and will cause gaps on
the bottom layer of your print. A little further and your print may get
knocked off, and very far you will be left with a spaghetti monster to clean
up.

Generally, having
parts start too far from the build plate will not cause as much damage to
your machine, but you will be left with wasted material and a cleanup on
your hands. There have been rare cases in which this mess of material
engulfs the hotend as it continues to print, and once cooled leads to a hotend
being submerged in a solid block of plastic. The cleanup from this can be so
extreme that it may warrant or require replacing hot end components. See
the end of the “Built up Material in Nozzle” chapter for a further
description of this.
Mechanically adjusting Z-height (printer
too far/close from bed)
Most machines come with an adjustable screw or lever that will run into
your Z-endstop when finding home (if not using an auto bed level sensor).
If your printer does not have an adjustable Z-height, I highly suggest
printing one.
Files for adjustable Z-height calibrations can be found on websites such as
Thingiverse, you will just have to find the correct one for your machine.
Being able to easily adjust the Z-height is key, because over multiple prints
these mechanical machines are very susceptible to slight variations (along
with just having different initial layer heights). You will want this screw to
have a spring keeping pressure on it in order to prevent as many minor turns
as possible throughout the rattling of the printer.
You will want your nozzle to be in a starting position where you can slide a
piece of paper under it, but so that it has some resistance. This distance will
be tweaked depending on the initial layer height, as mentioned later in this
section. I personally am able to tell what the proper z-height via sight is
since I have done so much printing, but you can always go this piece of
paper method as a starting point.
If this initial height is good, but the rest of your bed is not, you will want to
read from the “Unleveled Build Plate” chapter of this book.
You will want to make sure to auto home, then disable steppers, and check
this before starting a print because there are a lot of problems that can occur
from letting your printer continue at the wrong Z- height.
Initial layer height
The height of your first layer will drastically determine minor variations in
your Z-height.
This may seem intuitive, but it is very noticeable when printing different
degrees of quality parts. Printing in draft quality, or having your initial layer
height be close to 0.4mm on a large diameter nozzle, will allow you to start
prints much more simply than if you were to only be printing in very fine
quality. This is because there is a lot of leeway on this thick initial layer.
This mean that changing your nozzle diameter and layer height can change
your Z-height calibration. Using a very fine 0.25mm nozzle will cause your
printer to have to be much closer on the initial layer height than a printer
with a 0.6mm diameter nozzle.
Always max out your initial layer height based off your nozzle diameter
when using small nozzles. This means a 0.25mm nozzle should have an
initial layer height of around 0.18, even if the rest of your print has lower
layer heights. This will help you to find a good Z-height easier.
Variations based on material/temperature
As with all materials, glass and metal expands when heated. This means
that you should always be checking your Z-offset with the nozzle and bed
heated to your desired temperatures. This also unfortunately means that you
may have to tweak your Z-height based on what material you are printing
with. Printing with ABS on a 100°C build plate will likely require a slightly
different Z-height than printing with a low temp Nylon on a build plate that
is 45°C.
Changing the Z-height in the “Start G-
code” by adding a Z-offset
Along with mechanically changing the Z-height, you can also change it by
adding a positive or negative Z-offset to your start G-code. This is ideal for
when you have specific settings based on what layer height, nozzle you are
using, and material being extruded since you have a saved profile for each.
Having a Z-offset for each material profile you have is beneficial because a
heated build plate to 110°C will be closer to your nozzle than one that is
heated to 50°C, due to the expansion of your bed.
I actually don’t do this anymore since the auto bed leveler goes off of actual
distance from the build plate, instead of an endstop that is attached to the
frame. To do this though, you need to go to the Machine Settings on Cura,
but it might be elsewhere on other slicer software. Right under the section
in your start G-code of your Z axis finding home (G28 Z0), you will want to
add your Z-offset with G0 Z<position> as shown below:
 In the above
example, the nozzle will raise by 1.2mm after finding home and before
starting the print. So, if you found the perfect Z-height when using PLA, but
you have noticed you have to raise your nozzle roughly 1.2mm every time
you switch to ABS (which is pretty extreme), you could instead add this to
your ABS profile when slicing parts. This should reduce the amount of
times you have to mechanically adjust your Z-height, but will require you to
tweak all of your profiles based on initial layer height, material being used,
and nozzle diameter.
Here is a photo of what your print should look like when at the proper Z-
Height:
Summary of Fixes and Precautions
Mechanically adjust where your extruder runs into the Z-Endstop (if
not using an auto bed leveler).
Print additional parts if your printer does not have an adjustable Z-
height option.
Make sure to auto home before starting a print to make sure your
nozzle is not too close or too far when starting a print.
Increase the initial layer height in order to have an easier time
honing in on the correct Z-Height.
Small layer heights and nozzle diameters can lead to a lot of
headache honing in proper Z-height.
Recognize that different temperatures can lead to different Z-heights
due to the expansion of your build plate.
Create unique profiles with Z-offsets in the start G-code to reduce
the amount of mechanical adjust required (if not using an auto bed
leveler).
Tips if Still Not Working
While I tried my hardest for this book to be all inclusive for every printing
error, there may be a unique situation not covered that you can experience,
or at least one you cannot diagnose easily. Below are some good solutions if
you can’t fix your problem with any of the remedies described earlier.
Turn off machine and power supply for 10
seconds and turn back on
This used to be a running joke at our facility because it was surprising how
many times it fixed a problem. I would be frustrated for a half hour and
someone would yell out “Did you turn it off and back on?” We would then
laugh ironically as it actually worked.
For most problems it doesn’t hurt to turn off your machine and power
supply for 10 seconds and turn them back on.
Check frame for sturdiness and loose bolts
If you have been printing for a while without confirming all bolts on your
machine are tight, or you have an acrylic frame, you can experience minor
mechanical shifts resulting in ugly or failed prints.
Periodically examine your frame for any bends or loose bolts and fix or
tighten as needed. Review the “Mandatory Maintenance” chapter in this
book for proper precautions.
Flash firmware
This is another thing that is confusing but would work more often than I
would think. Sometimes re-flashing the firmware onto a machine that was
giving very strange failures would fix the problem. This isn’t possible with
a machine that hasn’t been bootloaded (CR-10 from the factory as an
example), but the vast majority of machines should be bootloaded with
Marlin to allow you to re-flash your machine. To learn how to bootload,
visit TH3D’s YouTube channel and website.
I go over how to flash your firmware in the “Over and Under Extrusion”
chapter, and elsewhere in this book. But if you do not have access to Marlin
and the original firmware, you can also do a factory reset with the “M502”
command. Just remember anything you changed (such as E-steps) since you
got your printer will be set back.
I actually do not need to do this quite as frequently as before, but it doesn’t
hurt to do periodically if you are experiencing hard to explain issues.
Re-slice G-code
There is a chance your G-code itself can be corrupted and you can fix your
error just by re-slicing and exporting a new G-code. This is covered in the
“Print Pauses Mid-Print” chapter.
Switch filament manufacturers
The quality of your filament matters. You could spend a full week trying out
all of the solutions described in this book and still not be able to achieve a
successful print if you are using subpar filament, or just old filament that
has absorbed moisture.
I don’t even bother with filaments that do not have high reviews and aren’t
made by well-known manufacturers, since their quality control is frequently
very poor. If you are buying a spool of PLA for under $15, you may have
found a great deal, but it is likely the company just doesn’t use high quality
PLA or have good quality control. Always read reviews, or check the
“Resources” chapter for some of my personal favorite manufacturers.
Search online and on YouTube
If you are having a problem, it is likely someone else somewhere has
experienced it. If you can search for your specific problem on Google to
find a forum or a thread somewhere where someone has successfully fixed
your issue. You can also search on YouTube.
I suggest subscribing to Thomas Sanladerer’s YouTube channel since he
covers an immense amount of 3D printing tutorials, and continually comes
out with new videos. He has personally taught me a lot of what I know from
these videos. His is definitely my favorite 3D printing tutorial YouTube
channel.
If you purchased a machine from a manufacturer who makes a lot of
printers, there is undoubtedly a review or two on YouTube. Just search your
printer name and you will likely find them.
There is also the 3D printing Facebook group. There are currently over
87,000 members as of editing this book, and most are extremely helpful in
diagnosing people’s prints. I frequently respond to individual’s problems,
and love to read other’s responses to help grow my own knowledge base.
Be humble and state you are having trouble with a specific issue while
including all relevant photos, and I can guarantee you will get some good
suggestions. Just don’t ask them what a good machine for under $300 is,
since that has become a running joke over there.
Send me an email
If you purchased this book and are still experiencing issues, feel free to
shoot me an email anytime at [email protected]. I have helped
many individuals just like yourself who just reach out to me, and a couple
of those problems have made it into this new 2020 edition. I may take up to
a full business day to respond, but I will do my best. The more detail and
photos you have for me, the easier it is.
Limitations Involved with 3D
Printing
3D printing is not a perfect end-all solution for manufacturing parts,
especially with today’s technology. The RepRap project started as a dive
into the unknown. Problems were addressed as they came and prints were
considered a success if they were useable at all. These early prints would be
considered unacceptable in today’s terms.
I compare today’s 3D printing market to that of using email in the mid
1990’s. Most machines are not plug-and-play and require a bit of
knowledge before you can even have one successful print. I’m not sure they
will ever be to the point where you need no background knowledge to use.
Almost all 3D printing manufacturers, especially those on Kickstarter, will
brag how their printer can be instantly used by anyone with any knowledge
for high quality parts - but there really isn’t a desktop machine like this.
Every single printer will have its own limitations and difficulties.
Unprintable models
I go over this in further detail in the “Model Errors” chapter, but the models
you can print are limited to the capabilities of your machine, and 3D
printing in general.

Walls and details

that are thinner than your nozzle diameter/line width will not be shown on
your final print. In the example above, Wolverine’s claws get thinner than
the line width I am using. This means the printer will not recognize them,
and your final print will look like the image on the right. If you need text to
show up in which the thickness of each letter is less than 0.1mm, you may
not be able to find a desktop 3D printer on the market that can achieve this
detail.
There are also issues involved with the need of support material. Since
gravity will always be a factor, FDM printing will have problems printing
clean overhangs. Not only will cleanliness of the underside of overhangs be
effected, but you will not be able to print specific models since you cannot
remove the support material.
You essentially will not be able to print any object entirely hollow unless it
is a sphere or comes to a rounded top. If you want to print a giant
rectangular cube, it will require at least 10% infill in order to have the top
surface print cleanly. A true hollow rectangle would require support
material, but there wouldn’t be a way to remove it, meaning you cannot
print one.
Active patents that prevent innovation
One of the things that prevented 3D printing from reaching the masses
sooner were a few integral patents. As with many blossoming industries,
unused or all-encompassing patents that have a long life span can prevent
people from innovating out of fear of being sued. Now that 3D printing has
grown into such a lucrative market, there are countless patents that currently
exist.
Some of these patents prevent innovation to enclosed build environments,
some to build plates, and others that encompass entire sections or methods
of printing. Many of these patents are actually expiring, which helps to
contribute to the amount of inexpensive machines that are popping up on
the market. Days where you were forced to spend $2,000 on a basic
machine are no more. There may be innovations to these patents that still
exist that are not currently even explored. We will hopefully see further
innovation as these patents expire over the next 5-10 years.
Print speed limitations
Barring a major change in the process used in FDM printing, there will
always be a limitation to just how fast a part can be printed. The better the
tolerances, the longer the print - there is no way around that.
Please refer to the chapter titled “Speed Limitations” for a more in-depth
explanation than given below.
Speed is also limited by the material you are using and the size of your
printer frame. Even if you had an extruder with an excessive amount of
torque that grasps tightly onto the filament, there are limitations involved
with melting each individual material composition. The filament needs to
melt to a good viscosity before it can be pushed out of the small nozzle
head, and this cannot be done instantly. Using a Volcano hotend will help,
but there will always be this limitation.
The new E3D Super Volcano can actually extrude at speeds so fast, that
they exceed what your frame is able to achieve. This is a great innovation
but it will cause your frame (or stepper/extruder) to be the limiting factor.
The larger your printed model is, the greater the speeds you will actually be
able to achieve as well. This is because your printer’s top speed is limited to
the space required to accelerate and decelerate your extruder. There is a
limit to any machine as to what speed it can actually physically ever get to
due to this space needed to accelerate and decelerate.
The last limitation is the frame itself. You don’t want your frame rattling all
over the place, which is why CoreXY and Delta machines can print faster
than Cartesians without the frame shaking. A shaking frame will lead to an
increased ghosting/echoing effect. This is especially true when you increase
the acceleration a lot in order to achieve your top speeds. You should see
my video titled “How Fast Can You 3D Print” to see more information.
Once again, refer to the “Speed Limitations” chapter for a further
explanation.
If you require speed when 3D printing, you may want to consider an
alternative 3D printing technology such as MJF or DLP over FDM. While
significantly more expensive, these technologies were developed to
drastically speed up printing and alleviate some other process limitations
found in FDM.
Upgrades and Purchasing a New
Printer
3D printing technology is rapidly improving and even purchasing this book
just two years from publication can have many of these failures fixed on
stock new machines.
These are parts that you may want to think about upgrading on your
machine, or what you should look for when purchasing a new printer.
Auto bed leveling/auto bed tramming
Five+ years ago, the vast majority of manufacturers that offered an auto bed
leveling system did not live up to their marketing. They were too
mechanical and overall did not work much better than just adding a few
extra end stops.
By 2018 you could purchase 3rd party auto bed leveling lasers, or buy a
machine that comes stock with one. Many of these work quite well and can
save you an endless amount of headaches that I describe in the “Unlevelled
Build Plate” chapter.

When using one

of these sensors, your extruder will travel to different sections of your build
plate at the start of a new print. The sensor will be able to tell variations in
how level your bed is and will change your printer firmware to
automatically tilt your model accordingly to compensate. These don’t
actually “level” the build plate, but rather make minor variations in your
initial z-height.
I personally use the EZABL by TH3D Studios, which can be purchased and
added to your machine for roughly $60 at TH3DStudio.com (confirm it
works on your machine first). This was a great upgrade since I always have
a level build plate now.
Surprisingly, even inexpensive machines are now adding these. I have a
$200 Tina2 sent to me by WEEDO for review which actually has one of
these stock as well. I would never have expected this to be the case a couple
of years ago when I released the first edition of this book. If you are
spending over $500 on your machine, it should hopefully come with one
stock.
These sensors will be mounted to your carriage, and you can find a model
for your printer setup on Thingiverse. You should watch videos on TH3D’s
YouTube channel, since Timothy covers a lot of issues and setup guides for
adding this to your machine. I also have a quick video where I go over this
on my YouTube channel titled “Paid Upgrades for the CR-10”.
Get thick threaded Z-axis rods
A great improvement to think of when buying your next printer is to see
how thick the threaded Z-axis rod/rods are. The thicker the rod and the
better it is housed into the frame, the longer your printer will last without
having tolerance issues.
Thick M10 threaded Z-axis leadscrews on a printer usually means the
printer will come with a higher price tag, but it is definitely a great upgrade.
Many well-built CoreXY machines have a single thick M10 leadscrew
which the build plate moves up and down on. Inexpensive Cartesian
machines will have a single M5 threaded rod, while better versions will
have two M8 leadscrews.
I have a video in which I go over this exact process titled “Upgrading your
3D Printer to 8mm Leadscrews” on my YouTube channel.
Upgrade hotend
Many high end printers come stock with a well-made hotend. There are
quite a few options out there, but I always suggest buying from a reputable
manufacturer - do not try and save money by buying cheap knockoffs.
All metal hotends do not need a Teflon tubing going all the way to the heat
break, meaning you can print much hotter materials. Having the Teflon
tubing go all the way to the heatbreak will make it so you can’t print as hot
without deforming the tube. All metal hotends fix this issue.
I have personally standardized to E3D hotends, and it honestly seems like
most of the 3D printing community has as well. They are well made, all
metal, and have a variety of nozzle options. The extremely popular and
well-made Prusa MK3S, Lulzbot TAZ machines, all the way to the
expensive Raise3D machines all use E3D hotends stock.
E3D has a wide array of nozzle diameter choices, are well- made, and seem
to experience minimal amount heat creep. And if you do experience a
nozzle clog, they are easy to disassemble. You can see all of these options
over at MatterHackers.com
If you find a different hotend that you prefer, you should definitely go for
that. Just make sure you watch any relevant reviews first and be extremely
cautious of attempting to save money from off brand versions.
Replacing a poorly made or very old hotend can drastically reduce failures,
increase the amount of materials you are able to print, and improve the
quality of your parts.
Well-made geared extruder
A stock extruder without any added gear ratio cannot print nearly as fast as
a well-made geared extruder. You can print the parts for a geared extruder,
but there are manufacturers that produce these extruders with some added
benefits to the tolerance and quality.
Without a gear ratio you will be limited to only printing stiff materials,
since any flexible version will not really be possible. The same is true with
nozzle diameters. Attempting to print on a nozzle with a diameter smaller
than 0.3mm will almost certainly require a gear ratio. Both of these facts are
even truer when using a Bowden printer instead of a direct version.
For instance, E3D also makes their Titan Extruder. This is a well-built,
light, geared extruder.
My personal favorite, as mentioned elsewhere in this book, is the Bondtech
BMG dual drive extruder. This extruder not only has a 3-1 gear ratio, it also
has two sets of teeth gripping onto the filament, rather than just one pushing
against a bearing as with all other extruders. If you can’t print with one of
these extruders, you likely can’t print with any extruder. Unfortunately it
costs $100 right now, but I am very happy I upgraded.
These can be used with a Bowden setup with an extra part, or can be used
on direct drive machines with an E3D barrel without any extra parts needed.
I bought mine over at MatterHackers.com.

Ever since
switching to this Bondtech extruder, and setting it up to be direct instead of
Bowden, I have been able to print every material and in every nozzle
diameter with zero issues. Definitely worth it in my opinion.
NOTE: As of editing this book, a new extruder/hotend combo has been
announced by E3D called Hermes. This is a part that has both the extruder
and hotend as one unit, meaning it will reduce the weight and space it
would take to have them as separate unit. But that isn’t the best part, as E3D
has joined Bondtech as making this extruder dual drive.
I have yet to test out Hermes, but the results I have seen from people in the
community really astound me. People are able to print extremely difficult
flexibles, such as Ninjaflex, at ridiculously high speeds. While I normally
limit my speeds to around 25mm/s for Ninjaflex, the examples I have seen
have had the Hermes printing it at up to 100mm/s - something I once
thought impossible. Be sure to research this extruder if you plan on
upgrading your machine.
Cartesian vs CoreXY vs Delta
There are benefits to each of these types of printers, but the vast majority of
machines you will see on the market are Cartesian, with CoreXY being the
second most common. When I say CoreXY, I generally mean a gantry
system, and CoreXY is one type of these gantry systems. You can also find
it in an H-Bot variety, I will just refer to the bed moving down as CoreXY
as to not confuse you further.
Delta printers seem to be able to print the fastest, but are difficult to
calibrate and must be tall if you want to print wide objects. Personally, I do
not have extensive experience with delta machines. There will be less
tutorials for these types of machines vs. Cartesian and CoreXY.
CoreXY printers have been growing in popularity and they definitely have
added sturdiness and benefits. I personally like CoreXY machines the most
for quality, but have a bit more experience on Cartesian models, due to
them being more popular over the past decade. Printers such as the Zortrax
M200 and Makerbot Replicator 2 are CoreXY machines.
CoreXY machines have the benefit of not moving the build plate back and
forth. This constant moving of the build plate will not only have extra wear
and tear on your printer, but can result in parts getting knocked over easier
with an increased chance of ghosting.
Because of this, CoreXY machines have become my favorite type of
printer. When looking to purchase a new printer, it is worth seeing if you
prefer CoreXY (gantry) over Cartesian.
Enclosed machine
I go over this added benefit in the “Warping” chapter in this book, but it is
highly beneficial to purchase a machine that has its build area at least
somewhat enclosed when printing with warping materials. This way you do
not have to worry as much when wanting to print in materials that have a
high internal stress. You just need to make sure your board is not enclosed
with the printer, since you don’t want that overheating.
Personally, I only have one enclosed machine. I do not use extremely high
warping materials very often, and my open frame does a good job for the
vast majority of my prints. For me, spending the extra money on an
enclosed machine is not really worth it. You will need to determine if it
makes sense for you, or if you can get away with printing non-warping
materials (including the warp-free technology that Polymaker now offers).
Metal frame
If you haven’t noticed already, I highly suggest purchasing a printer with a
strong metal frame. Acrylic framed printers will not hold up over time and,
in my opinion, it is entirely worth upgrading to metal.
I will not bother with acrylic machines or any printer that is not sturdy. It’s
all metal or nothing for me now due to the headaches I have had in the past.
V-Slot Aluminum Extrusion
3D printers on the market are increasingly offering v-slot aluminum
extrusions for their frame instead of linear rods. These rails use a stiff,
aluminum rail along which the carriages slide. It accomplishes this with
rollers that roll on the rails. This is opposite a linear rod printer where the
carriages are attached to a smooth rod via bearings.
The vast majority of printers a couple of years ago used linear rods, but it
seems to be changing. This is due to an increasing amount of makers
preferring v-slot aluminum extrusions. Aluminum rail printers are often
much stiffer and more precise with smoother motion. I personally prefer
aluminum extrusion and linear rail printers now, though it does depend on
the particular machine.
24V instead of 12V
Most inexpensive 3D printers come with a 12V power supply and output.
Buying a printer that is 24V will come with a few added benefits. These
include a shorter time required to heat your build plate, more torque to your
stepper motors (reduces extruder stepper skipping and allows for faster
prints), and results in less noise produced by your stepper motors.
If you are building a printer from scratch, just make sure any upgrades you
purchase are rated for 24V. If you are converting your printer to 24V, you
will need to change your hot end heater cartridge, your heated build plate
(or at least the wiring to it if your build plate can handle 24v), and you must
remove a specific diode on a RAMPS board. If you are doing this upgrade
yourself, you must watch tutorials and be sure you are confident in what
you are doing. If not confident, don’t do it.
Keep in mind a 24V machine is likely going to be more expensive than their
12V counterparts, though that is not always the case. Do some research on
the particular machine you plan on purchasing and if it being 24V is
beneficial to you.

1.75mm vs 3.00mm Filament

This debate has been going on for years and there is still no specific answer,
though it seems that 1.75mm has slowly won. I have extensive experience
using both, and personally I like to use 1.75mm more.
3.00mm filament (more accurately it is 2.85mm filament) has a tighter
tolerance in its diameter than 1.75mm filament does. This should
theoretically mean parts should come out cleaner and you should experience
less nozzle clogs, but I do not notice much of a difference in this vs.
1.75mm printers. You can print parts a bit faster though because less torque
is required on your extruder stepper since less distance is required to
extrude the same amount of material. This means your extruder can turn
slower when dealing with 3.00mm filament (possibly leading to less
extruder motor skips).
The biggest issue with 2.85mm filament is with its want to curl back onto
its spool. When you are near the end of a 2.85mm PLA spool, you can
experience an extensive amount of breaks in the filament due to it wanting
to curl back into a circle.
This is far more annoying than you can imagine if you haven’t dealt with it
yourself. This factor alone has made me prefer 1.75mm filament, since it is
far easier to manipulate and you don’t ever have to throw away spools that
still have 30 grams of material on them. I see no quality differences with
1.75mm and the headaches involved with using it are far less. You may
prefer 2.85mm, I have just come to like 1.75mm.
Poll Results
I actually held a poll on my Twitter page to see what people refer the most.
Everyone has their own reasons for liking one of the options below, but I
figured I would see what the majority of people like.
While there were only about 40 participants, the results were as follows. I
will hopefully have a larger sample size later, but this is just so you can see
what people think.
I asked what their preferred method of each of these were:
Build Type:
Cartesian: 14%
CoreXY: 79%
Delta: 7%
Extruder Type:
Bowden: 0%
Direct: 100%
Filament Diameter:
1.75mm: 91%
2.85mm: 9%
Extruder Brand:
E3D Titan: 33%
Bondtech BMG: 67%
Hotend:
E3D V6: 47%
E3D Volcano/SuperVolcano: 47%
Slice Mosquito/Mosquito Magnum: 6%
Frame:
Linear Rail or V-Slot Aluminum Extrusion: 89%
Linear Rods: 11%
So it seems that the average person in this polling agrees with my personal
favorite methods. I have come to like CoreXY more than Cartesian, Direct
over Bowden, and rails over Linear Rods. By the time you read this book
there may be new hotend and extruders that people like (such as the Hermes
I made a note of), so always see what is popular by looking at new videos
and reviews online.
Resources
Below are some great resources you can use to help you in your 3D printing
exploration.
Video Tips and Tutorials
The 3D Print General (Myself) YouTube Channel
Thomas Sanladerer YouTube Channel
3D Maker Noob YouTube Channel
CNC Kitchen YouTube Channel
Joseph Prusa YouTube Channel
Maker’s Muse YouTube Channel
Make Anything YouTube Channel
3D Print Nerd YouTube Channel
Teaching Tech YouTube Channel
CHEP Filament Friday YouTube Channel
TH3D Studio YouTube Channel
Other Resources
Facebook 3D Printing Group (very helpful group of people)
TH3DStudio.com
Free 3D Models For Download
Thingiverse.com
MyMiniFactory.com
Cults3D.com
GrabCAD.com
Yeggi.com (compiles 3d models from many different sites, including those
that cost money)
Free Software
Cura for slicing parts
Prusa Slicer for slicing parts
Tinkercad.com for editing .stl files
MeshMixer for editing models
Autodesk Fusion 360 for editing and creating models. Just sign up as a
“Start-up or Enthusiast” to not pay legally
3D Builder for Windows 10 for editing models
Repetier Host for directly connecting to printer
Octoprint for connecting multiple printers to a network
Places to Purchase Printer Parts
3DPrintGeneral.com – where I link to many of the parts I use. I do not sell
them, just link to where you can purchase them.
MatterHackers.com – my favorite for finding reputable parts
Amazon.com – be careful to not accidentally purchase off-brand from a
non-reputable seller
TH3DStudio.com - Tim makes sure all of the parts he sells are of high
quality and sourced properly
Fillastruder.com for E3D parts in the United States
E3d-online.com for Europe
Prusa3D.com
Newegg.com
DigiKey.com
Mouser.com
Reputable PLA ABS and PETG
Manufacturers
Polymaker
Hatchbox
AIO Robotics
Proto-pasta
Prusament
Esun
IC3D
Overture (I have begun using this a lot due to its low price)
Reputable Unique Material Manufactuers
Polymaker
3DX Tech
taulman3D
MatterHackers
NinjaTek
Proto-Pasta
ColorFabb
Fiberlogy
My Favorite 3D Printers (Pre-Built)
$ - Creality CR-10 or Ender 5 (best price for what you get, though you may
want to do upgrades). There are many clones of this style of build that are
all at a great price point as well.
$$ - Prusa i3 MK3 (highest praise in the community. A real workhorse)
$$$ - Lulzbot TAZ Pro (was my favorite printer, though there are so many
other options now available that are less expensive)
$$$ - Zortrax M200 or higher (great surface quality)
$$$$ - Ultimaker 3 or higher (easy to use, I personally do not like this for
the price, but good for newbies and educational settings)
$$$$$ - Raise3D (large, enclosed printer. Great for real production but not
necessarily for personal use due to its price)
There are many other printers that are great that I haven’t tested, just make
sure you watch review videos before purchasing.
Places to Order Prints
SD3D.com
Shapeways.com
ProtoLabs.com
Visit all3dp.com for their article on “Best Online 3D Printing Services” for
a more expansive list.
About the Author

Sean Aranda began his 3D printing explorations by

becoming the Operations Manager for SD3D in early 2015. Along with
adding innovations to the 3D printing industry, SD3D is a production
service provider for everyone from inventors to large businesses. With over
a dozen FDM machines and a few hundred clients, Sean was able to amass
well over 50,000 hours of successful printing.
Sean was also able to receive extensive experience with material variations
and profile settings required for a successful print, since SD3D offers over
16 different types of FDM 3D printing materials.
While he had a very basic background before starting at SD3D, Sean’s
knowledge of printing failures grew rapidly as he helped all clients get a
usable 3D print within the promised timeframe. Whenever a printer failed
or had a malfunction, Sean was in charge of all maintenance and repairs.
Sean has also authored a much smaller graphic handbook for 3D printing
called The A-Z 3D Printing Handbook, which has amassed well over 5,000
downloads. This is the third edition of this book, the first two selling
thousands of copies helping the community to achieve consistent,
successful prints.
Since releasing the first edition of this book, Sean has been growing a 3D
printing channel titled “The 3D Print General” where he goes over fun
prints and in-depth tutorials. In these three years of videos he has easily
added another 25,000 hours of successful printing with his half dozen
machines. These videos are meant to fill in the gaps from this book and to
show first hand examples of how you can fix your 3D printing failures.
Many of the topics covered in this book have been covered on this YouTube
channel in a 5-10 minute video.
A lot of what you are reading in this book is from shear testing over the
course of two years of full time manufacturing across dozens of machines
and countless hours for his YouTube channel, as well as updates that have
occurred in the three years since. It also includes any issues that readers of
those first two books have contacted him on – but were not in those
editions.
But it definitely wasn’t all trial and error, the 3D printing expert, co-founder
of SD3D and editor of this book, David Feeney, was always around to
educate.
About the Editor

One of the few people you will meet with a drastic

amount of more 3D printing experience than Sean is David Feeney. David
is an experienced manufacturing engineer, project manager and
entrepreneur. With six years of direct experience in the automotive and
industrial equipment industries as a manufacturing engineer and project
manager, David understands the needs of the target client extremely well.
Prior to co-founding SD3D, David worked at Aptera Motors as a project
manager for over a dozen electrical and mechanical engineers. David later
worked as a manufacturing engineer for the Large Compressor Set and
Mechanical Drive (LCSMD) division for Solar Turbines. In this role David
was solely responsible for fixing any design or manufacturing issues prior
to hitting the assembly line on over $100 million worth of equipment
annually. David holds a bachelor’s of science degree in mechanical
engineering from San Diego State University and is EIT accredited with the
California Board for Professional Engineers.
Mr. Feeney is the head of the technology upgrades at SD3D and is utilizing
his hundreds of thousands of hours of successful 3D printing by helping to
advance the entire industry. Visit SD3D.com now to find out more!
Whether you are new to 3D printing, or you have dozens of successful
prints under your belt, this book is going to help you!
Sean Aranda and David Feeney have hundreds of thousands of successful
3d printing hours combined, so let them help you achieve consistent clean
prints.