What are some advanced techniques and tools for measuring and adjusting layer height in 3D printing?

1 Calibrate your extruder and bed

Before you start printing, you need to make sure that your extruder and bed are properly calibrated, as they will influence the amount and consistency of material that is deposited on each layer. You can use a digital caliper to measure the diameter of your filament and adjust the extrusion multiplier accordingly. You can also print a calibration cube or a single-wall test print to check the accuracy and alignment of your extruder and bed. If you notice any gaps, over-extrusion, or warping, you may need to tweak the nozzle temperature, bed temperature, retraction, or leveling settings.

2 Use a layer height calculator

One way to find the optimal layer height for your printer is to use a layer height calculator, which is a tool that calculates the best layer height based on your nozzle diameter and the Z-axis resolution of your printer. The Z-axis resolution is the smallest increment that your printer can move along the vertical axis, and it is determined by the lead screw pitch, the microsteps per revolution, and the steps per millimeter. The layer height calculator will suggest a layer height that is a multiple of the Z-axis resolution, which will ensure a smooth and even surface. You can find online layer height calculators or use formulas to calculate it yourself.

3 Use adaptive layer height

Another way to optimize your layer height is to use adaptive layer height, which is a feature that automatically adjusts the layer height depending on the shape and complexity of your model. This means that you can use a lower layer height for curved or detailed parts, and a higher layer height for flat or simple parts, which will save time and material without compromising quality. Some slicers, such as Cura, PrusaSlicer, or Simplify3D, have built-in adaptive layer height options that you can enable and customize according to your preferences.

4 Use a layer indicator

Sometimes, you may want to measure or adjust the layer height during the printing process, for example, to check the progress, troubleshoot issues, or change settings. In this case, you can use a layer indicator, which is a device that displays the current layer number or height on a screen or a LED strip. You can either buy a ready-made layer indicator or make your own using an Arduino, a LCD display, or a Neopixel strip. You will also need to modify your g-code to include commands that send the layer information to the layer indicator.

5 Use a dial indicator

If you want to measure the actual layer height of your prints with high precision, you can use a dial indicator, which is a tool that measures the distance between two surfaces using a needle and a dial. You can attach a dial indicator to your printer's carriage or extruder, and move it along the Z-axis to measure the height of each layer. You can also use a dial indicator to calibrate your bed leveling or your Z-offset, which are both crucial for achieving consistent layer height.

6 Use a feeler gauge

Another tool that you can use to measure or adjust the layer height of your prints is a feeler gauge, which is a tool that consists of a set of thin metal blades of different thicknesses. You can use a feeler gauge to check the gap between the nozzle and the bed, which will affect the first layer height and adhesion. You can also use a feeler gauge to check the thickness of each layer by inserting the blades between the layers and finding the one that fits snugly. A feeler gauge can help you verify the accuracy of your layer height settings and make adjustments if needed.

7 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?