How can you avoid warping and cracking when 3D printing with ABS?

1 Choose the right printer and settings

Not all 3D printers are suitable for printing with ABS. You need a printer that has a heated bed, a closed or semi-closed chamber, and a nozzle that can reach at least 230°C. These features will help maintain a consistent and high temperature throughout the printing process, reducing the risk of warping and cracking. You also need to adjust your slicer settings accordingly, such as increasing the bed temperature to 100-110°C, decreasing the cooling fan speed or turning it off, and using a raft or a brim to improve bed adhesion.

2 Use a suitable surface and adhesive

Another factor that affects warping and cracking is the surface and adhesive you use for your print bed. ABS does not stick well to bare glass or metal, so you need to apply a layer of something that can bond with ABS and resist high temperatures. Some common options are Kapton tape, PEI sheet, ABS slurry, or hairspray. You can also use a glue stick, but make sure it is compatible with ABS and does not leave any residue. Whatever you choose, make sure you clean your bed regularly and apply a fresh layer of adhesive before each print.

3 Control the ambient temperature and humidity

The ambient temperature and humidity of your printing environment can also affect the quality of your ABS prints. Ideally, you want to keep the temperature around 25-35°C and the humidity below 50%. This will prevent the ABS from cooling too fast or absorbing moisture, which can cause warping and cracking. You can use a thermometer and a hygrometer to monitor these conditions, and use a heater or a dehumidifier if necessary. You can also cover your printer with a box or a tent to create a more stable microclimate.

4 Optimize the print orientation and design

Sometimes, the way you orient and design your model can make a difference in how it prints with ABS. For example, printing large flat surfaces or thin walls horizontally can increase the chances of warping and cracking, as they are more prone to shrinking and curling. You can try to print them vertically or diagonally, or add some chamfers or fillets to reduce the stress concentration. You can also use supports, infill, or shells to reinforce your model and prevent it from collapsing or splitting.

5 Post-process your print carefully

Finally, after you finish printing with ABS, you need to post-process your print carefully to avoid damaging it. First, let your print cool down completely on the bed before removing it, as it can still warp or crack if you force it off while it is hot. Second, remove any supports, rafts, or brims gently, using a knife or a plier, and sand or file any rough edges or blobs. Third, if you want to smooth or polish your print, you can use acetone vapor or sandpaper, but be careful not to overdo it or expose yourself to harmful fumes.

6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?