Support Material Buckling on Large Prints

[gestalt73]

I'm curious if anyone else has seen this with the support material during large prints.

Rostock Max
E3D V5 hotend
Kisslicer, course support
20 perimeter, 30 infill, 40 sparse infill
bed at 120c
printing at 270c (any lower and the model splits multiple times)

It looks to me that its some type of additive buckling. each layer for some reason slightly compresses the previous one, but it's always the right side of the model regardless of the model's rotation on the build plate.
I've tried it with sheath main support as well, and the buckling still occurs. (Although the edges turn out alot better, no splitting when sheath main support is selected)

It's an annoyance with single head printing, but the buckling interferes with the second head and makes dual extruder prints problematic

In the first image, you can see the support layers buckling on the right hand side of the model. That side always buckles, regardless of the models rotation on the build plate.

In the second image, you can see the buckling from the side view. These are two different prints of the same part.

[img]http://imgur.com/hJA9V5N.jpg[/img]

[img]http://imgur.com/yYmdhUK.jpg[/img]

[notarat]

I've seen that behavior on my FFCreator X several times and I increased the density (very slightly) of the layout of support material in my slicer program which seems to eliminate or greatly reduce the amount of collapsing I see.

I haven't played around with the slicer settings for my Rostock Max V2 (because I haven't opened it and put it together) but I would think there is a setting in Repetier(?) which allows you to change the density or pattern (or both) which would reduce the collapsing you see. As for why it happens on the right side, I have no clue. Sorry

[gestalt73]

Interesting. Are you talking about

- increasing the density of the fill pattern (closer lines in fill pattern)

or

- increasing the thickness of each fill line

I suspect that it's happening on the right hand side because of how the support structure is laid out.
It's almost like there's a certain maximum line length before the curling and buckling occurs.
You can kind of see that happening from about the center of the print. That first support line that cuts across the middle is the longest run, as well as all the support lines after it.

I wonder if that's something that the KISSlicer author can take into account during support placement and slicing.

[notarat]

Interesting. Are you talking about

- increasing the density of the fill pattern (closer lines in fill pattern)

or

- increasing the thickness of each fill line

I suspect that it's happening on the right hand side because of how the support structure is laid out.
It's almost like there's a certain maximum line length before the curling and buckling occurs.
You can kind of see that happening from about the center of the print. That first support line that cuts across the middle is the longest run, as well as all the support lines after it.

I wonder if that's something that the KISSlicer author can take into account during support placement and slicing.

The density of the support material that is printed is what I'm referring to. When I make support density too low, the support material collapses like that.

I use Simplify 3D and Makerware for my Creator X and Replicator 2 and, in those programs, I can increase the value setting for how thick the support material prints so it does not collapse. It does make it a little harder to remove when the print is done so, if you have the ability to change the value in Repetier(?) you should increase it in small increments just to the point it doesn't collapse