Gap in prints on all parts

[AEK]

Hello,

I have printed these 4 parts over 3 time and I get the same results every time.

At around the 35th layer (0.25mm) it seems to create a gap all across the board (as shown in pictures).
I tested other parts because I though maybe it's a mechanical issue but the others parts printed fine.
Tried with support and without, didn't make a different.

They were designed in SolidWorks.
I'm using Simplify 3D, 40mm/s, 30% infill, Printer: Rostock max v2.
I'm really new at 3D Printing, Any help would be appreciated.

Andre

[Mac The Knife]

What material, and at what temperature are you using? If abs, are you using a layer fan?

[Jimustanguitar]

I'm guessing that this is a temperature thing. The parts are failing right at the peak of the arches, so it's where the surface area of each layer jumps way up and takes longer...

More details please, what material, temps, speed, fans, etc are you using? (like Mac said above)

[AEK]

Yes off course forgot to mention.
Printing PLA at 190c / 50c / 40mm/s one layer fan

I just printed it in Matter Control with Cura engine and it did not have that problem.

[AEK]

It seems like it's happening at the peek of the aches like you mentioned,
I also noticed it lays more down at the peek than the infill area causing an unbalance "if than makes any sense"
I'm printing it now at 100% infill to see what happens with Simplify 3D
-PLA at 190c / 50c / 40mm/s max overall / one layer fan / 0.25mm layer height /

[AEK]

This is what's happening, see pictures.
It's raising at the tip or the arch way, but this time because I have 100% infill it managed to make it work.
but the lesser the infill the problem will happen.

[geneb]

I can tell you right now that your problem is caused by insufficient cooling. The first photo in the post right above mine shows the curl in the plastic that shows that. Slow the print speed down, print more parts at once or make sure the fan is at 100%. (or a mix of all three if the parts are really small)

g.

[AEK]

I guess I will order the other two fans. Thanks!

[geneb]

One fan should be plenty for that part. Try slowing it down and make sure your fan is at 100%.

g.

[mhackney]

I agree with geneb but also think you should be aware - that part geometry looks like a "perfect storm" for bad results with Simplify3D's poor infill quality. You can see it in the photo of the part you are holding where it has separated. That and the lack of cooling are creating problems. You may be able to compensate for the infill with cooling or by increasing to 100% infill as you've done. That, however, will make the cooling even more critical.

Perhaps one of the S3D users here like jfettig can help with a better infill configuration too.

[AEK]

I agree on the bad S3D infill quality. there isn't a lot of infill options either. I printed this In MatterControl/Cura and did not have this issue but unfortunately the overall print quality and perimeters
are not as good as S3D.

I'm printing at 40mm/s and around 30mm/s perimeters. Wouldn't that be considered slow enough?

[geneb]

The problem is that the parts are so small that there's not enough time for them to cool enough to not curl like you see in the photo. Set a minimum layer time of 30 seconds or so, or just add more parts to the job.

g.

[geneb]

I would also recommend a perimeter speed of 20-25mm/sec if you want really nice looking exterior surfaces.

g.

[AEK]

I will give that a try like you suggested.

[JFettig]

I never print PLA so I'm not sure how much help I can be, one of the biggest things that help in the latest releases is the infill extrusion width - stock it was at 100% maximum, as a bandaid they allow you to turn it up, Try 150 or 200% infill extrusion width. It fills all the gaps. Make sure "random infill" is turned OFF.

How many borders are you printing? I find that printing many borders with materials that need cooling will warp upwards like that. Fewer borders seem to help, I usually print 2-4 borders but on a big overhang like that, it might be better to print fewer.

[AEK]

Just about to do more testing...
I had set at 2 perimeter, infill ext width was at 150.

[AEK]

I tried a cube test with infill extruder at 200% and did a great job. Much better than the standard infill.

I was also playing around running 2 processes, each had different angle infill but unfortunately it reapeated everything else with it.

Going to try to get the additional fans tomorrow and try my parts with the problem again and hopefully the fans will help on that peek area.

Layer time speed is 40sec, parts looking much better.

Thank you for you help!

[teoman]

Try to be patient and try one thing at a time so you know what solved the problem.