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You're struggling with 3D printing problems. What can you do to fix them?

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3D printing is a fascinating and versatile technology, but it can also be frustrating and challenging when things go wrong. Whether you are a hobbyist, a student, or a professional, you may encounter various 3D printing problems that affect the quality, accuracy, and reliability of your prints. How can you fix them? In this article, we will share some tips and tricks to help you troubleshoot and solve some of the most common 3D printing issues.

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Erencan Bulut

Robotics Research Assistant @Fraunhofer CML | M.Sc. @TU Hamburg

1 Clogged nozzle

One of the most annoying 3D printing problems is a clogged nozzle, which can prevent the filament from extruding properly and cause under-extrusion, blobs, or gaps in your prints. A clogged nozzle may be caused by using low-quality filament, printing at the wrong temperature, or leaving the nozzle idle for too long. To fix it, you can use a needle or wire to poke the nozzle and clear the blockage, being careful not to damage it. Alternatively, you can heat up the nozzle and use pliers to pull out the filament. You may need to cut off the melted end before feeding it back into the extruder. Another option is to perform a cold pull or an atomic pull, which involves heating up the nozzle, inserting a cleaning filament or a different material, and then cooling it down and pulling it out quickly. If the clog is too severe or the nozzle is worn out, you may need to replace it with a new one.

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Joseph Ulsh

Biomedical Engineer | Medical Devices, Bioprinting, Orthopaedics
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When troubleshooting a nozzle clog I have often found that a part of the print had bad adhesion so the material that should have been added to the print just hangs on and around the nozzle. Your printer's manual will probably have tips for improving layer adhesion on the print surface. After the first layer, though, the adhesion issues will be with the previous layers of the print itself. Sometimes, slowing the step with the bad adhesion (for example reducing travel speed during a tight corner) down can help in that case.

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Charles A

Senior Mechanical Design Engineer at BlackBoost | Ex. Bonfiglioli Transmission Private Limited | Performance parts Design | Industrial Gearbox | Topology optimization | Soildworks | 3D scanning & 3D printing|
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Heat the nozzle: Raise the temperature of the printer's hot end to melt any clogs. Clean the nozzle: Use a needle or fine wire to carefully unclog the nozzle, being cautious not to damage it. Use cleaning filament: Specialized cleaning filaments can help remove debris and unclog the nozzle.

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2 Warping and curling

Warping and curling are 3D printing problems that occur when the edges or corners of your print lift up from the build plate, resulting in a distorted or deformed shape. These issues are usually caused by poor adhesion, uneven cooling, or excessive shrinkage of the material. To prevent or minimize warping and curling, you can use a heated bed and set the appropriate temperature for your material to reduce thermal stress and contraction. Additionally, applying an adhesive or a coating to the build plate can help improve the grip of the print. Furthermore, adjusting the nozzle height and first layer settings is essential for a successful print. You can also use a brim, a raft, or a skirt to increase the surface area and stability of the print. Lastly, enclosing or covering your printer can maintain a consistent temperature and airflow around the print.

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Charles A

Senior Mechanical Design Engineer at BlackBoost | Ex. Bonfiglioli Transmission Private Limited | Performance parts Design | Industrial Gearbox | Topology optimization | Soildworks | 3D scanning & 3D printing|
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Adjust the bed temperature: Increase the bed temperature to ensure better adhesion of the printed object to the build plate. Use a heated bed or enclosure: A heated bed or enclosing the printer can help maintain a consistent temperature, reducing warping.

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3 Stringing and oozing

Stringing and oozing are 3D printing problems that occur when the filament leaks or drips from the nozzle during travel moves, leaving thin strands or blobs of material between different parts of the print. These issues are commonly caused by improper retraction, incorrect temperature, or high printing speed. To reduce or eliminate stringing and oozing, you can enable retraction and adjust the retraction settings in your slicer software. This feature pulls back the filament from the nozzle when it is not extruding, preventing it from leaking or oozing. Additionally, lowering the nozzle temperature and the printing speed can avoid overheating or over-extruding the filament. You may need to experiment with different settings to find the optimal balance for your material and printer. Increasing the travel speed and the travel acceleration can minimize the time and distance that the nozzle travels without extruding, which can reduce the amount of filament that leaks or oozes from the nozzle. Finally, using a coasting or a wiping feature can reduce the pressure and flow of the filament at the end of each extrusion. Coasting stops the extrusion slightly before the end of the path, while wiping moves the nozzle along the edge of the print to remove any excess material.

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4 Layer shifting and misalignment

Layer shifting and misalignment are 3D printing problems that occur when the layers of your print do not line up correctly, resulting in a skewed or distorted shape. These issues are typically caused by mechanical issues, such as loose belts, faulty motors, or jammed rods. To address the problem, you can check and tighten the belts, screws, and pulleys of your printer; lubricate and clean the rods, bearings, and rails; calibrate and level the bed and the print head; and reduce the jerk and acceleration settings. Doing so will help ensure that the print head or the bed is not moving inaccurately or inconsistently, that they are not dirty or obstructed, that they are aligned and parallel, and that sudden or rapid changes in speed or direction are avoided.

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Charles A

Senior Mechanical Design Engineer at BlackBoost | Ex. Bonfiglioli Transmission Private Limited | Performance parts Design | Industrial Gearbox | Topology optimization | Soildworks | 3D scanning & 3D printing|
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Check the belts: Ensure that the belts driving the printer's axes are properly tensioned and aligned. Tighten screws and bolts: Make sure all screws and bolts on the printer are tightened securely, especially those holding the print bed and gantry in place. Reduce print speed: Slow down the printing speed to reduce the likelihood of missed steps and layer shifting.

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5 Poor surface quality

Poor surface quality is a 3D printing problem that can affect the appearance and texture of your print, making it look rough, uneven, or bumpy. This issue can be caused by various factors, such as improper slicing, incorrect calibration, or environmental conditions. To improve the surface quality of your print, you can optimize the layer height, infill, and top and bottom layers settings in your slicer software. Additionally, calibrate the extrusion multiplier, flow rate, and nozzle diameter settings for consistent and accurate extrusion of the filament. You may also need to use a cooling fan and fan duct to control the cooling of the print and prevent overheating. Post-processing your print with sanding, polishing or painting can also smooth out any imperfections or defects on the surface. Balancing resolution, strength and printing time is key for achieving a smooth and solid surface finish.

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Erencan Bulut

Robotics Research Assistant @Fraunhofer CML | M.Sc. @TU Hamburg
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It's essential to consider not only slicer and calibration adjustments but also material choices. Using high-quality filaments, experimenting with different printing temperatures, and ensuring proper storage of filaments can significantly impact the surface finish. Moreover, exploring advanced post-processing techniques like acetone vapor smoothing or specialized coatings can further enhance the overall aesthetics and quality of your 3D prints.

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Charles A

Senior Mechanical Design Engineer at BlackBoost | Ex. Bonfiglioli Transmission Private Limited | Performance parts Design | Industrial Gearbox | Topology optimization | Soildworks | 3D scanning & 3D printing|
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Check the filament quality: Low-quality or improperly stored filament can lead to poor surface quality. Use high-quality filament from reputable manufacturers. Adjust print settings: Experiment with different print settings, such as layer height, print speed, and temperature, to achieve better surface quality.

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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?

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You're struggling with 3D printing problems. What can you do to fix them?

1

2

3

4

5

6

1 Clogged nozzle

2 Warping and curling

3 Stringing and oozing

4 Layer shifting and misalignment

5 Poor surface quality

6 Here’s what else to consider

3D Printing

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You're struggling with 3D printing problems. What can you do to fix them?

1

2

3

4

5

6

1 Clogged nozzle

2 Warping and curling

3 Stringing and oozing

4 Layer shifting and misalignment

5 Poor surface quality

6 Here’s what else to consider

3D Printing

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