3D Printing: What can cause a sudden loss in the inter-layers of my prints? (4 Solutions!)
Channel: Roel Van de Paar
Date: 2019-06-24

3D Printing: What can cause a sudden and dramatic loss in the inter-layer registration of my prints?


The Question: Suddenly, my printer has started producing prints that have a very pronounced
layering. Normally, the alignment between layers is very good, and the prints
look very smooth. Suddenly, the prints have become much worse and the layers
are misaligned with respect to each other.
[enter_image_description_here]
The part on the left is my "normal" quality, while the part on the right show
the deterioration. Here is another picture (in which the good part is on the
right):
[enter_image_description_here]
The parts are both printed with 0.1mm layer height, and identical slicer
settings/filament. I am printing on a custom-built FDM printer; the mechanism
is roughly similar to that of an Ultimaker.

Solutions Sample (Please watch the whole video to see all solutions, in order of how many people found them helpful)

== This solution helped 4 people ==
There are many factors, here are a few things to check:
I'd first suspect filament feeding. This type of ridging can be caused by a
filament coil that is binding occasionally, or a filament that doesn't have an
even diameter or volume per length. Binding within the filament feeder and
feeder tubes can also be a cause. Bubbles in the filament, or sometimes a
mismatch between the filament ideal temperature and the head temperature could
create results like this, but it probably wouldn't vary so much between the
layers.
Next I'd look at the print head. If it has blockages, or poor temperature
control this could result.
Lastly, I'd check the mechanisms - disconnect the motors and see if all the
carriages slide smoothly without any binding, particularly the Z axis. It
doesn't look like you're missing steps, but binding here may result in greater
backlash, which could result in similar ridges. Make sure any belts and gears
are tight.

== This solution helped 4 people ==
As with many topics in 3D printing, there can be many variables that produce
this result.
Immediately, your images make me think that the belts on your machine are not
tight enough. This can cause noise in every direction of movement and is more
prominent in backlash areas. I would suggest going through your general
maintenance checklist:
 * Replace Build Plate tape
 * Level build plate (An uneven plate or improper height can yield these
 results as well)
 * Teach your axis belts
 * Clean/lube guide rails
 * Clean drive gears
Keeping up on your maintenance (I do mine about every 5 prints) should reduce
noise in your motion and ensure better quality prints, mechanically speaking.
As mentioned above, your results may be caused by your BP being leveled too low
(or too high). If your build plate height is off, the filament will not adhere
to previous layers very well (if too low) and can cause this back and forth
"spaghetti noddle" effect on outer layers. If the build plate is too high, you
might see the nozzle physically "spreading" the previous layer around as the
nozzle digs into the layer.
Another possible fix for this would be to play with the settings in your
slicing engine that involve the order that shell/roof/floor layers are printed.
ie Start inside-out or start outside-in.

== This solution helped 1 person ==
Have you recently leveled your print bed? By placing the nozzle too close to
the bed on the first layer the first layer will seem over extruded. If there
are no infill layers after the first layer, these layers will seem over
extruded as well since the extra filament will have nowhere to go.
A typical sign of too close bed leveling is that the bottom layers seem over
extruded, while layers after regions of infill appear normally extruded.

With thanks & praise to God, and with thanks to the many people who have made this project possible! | Content (except music & images) licensed under cc by-sa 3.0 | Music: https://www.bensound.com/royalty-free-music | Images: https://stocksnap.io/license & others | With thanks to user Tormod Haugene (https://askubuntu.com/users/115), user Tom van der Zanden (https://askubuntu.com/users/26), user tbm0115 (https://askubuntu.com/users/98), user Robert Cartaino (https://askubuntu.com/users/1), user Adam Davis (https://askubuntu.com/users/16), and the Stack Exchange Network (https://3dprinting.stackexchange.com/questions/149). Trademarks are property of their respective owners. Disclaimer: All information is provided "AS IS" without warranty of any kind. You are responsible for your own actions. Please contact me if anything is amiss at Roel D.OT VandePaar A.T gmail.com.