FDM Print deformation

Complete Print but Deformed or Delaminating

• Warping, caused by internal stress in the print:
  • Too much cooling.
  • Bed temperature too cold.
  • Low print speed (prints cool more evenly at higher speeds).
  • Increase bed contact area (use a raft or sturdy brim).
  • Enhance binding to the bed (improve cleaning, use a better binding agent).
  • Utilize an enclosure and keep the printer away from drafts.

• Cracking/Delamination:
  • Print hotter and/or faster.
  • Poor or inconsistent cooling.
  • Use an enclosure.

• Elephant’s Foot (a sign of over-extrusion):
  • Poor bed leveling.
  • Chamfer the base during design.
  • Nozzle height too low.
  • Insufficient cooling.
  • Bed temperature too hot.

• Layers badly aligned (usually a maintenance problem):
  • Lower printing speed.
  • If the print head contacts the print during non-printing moves, increase Z height during these moves.
  • Ensure the printer is secure and hard to knock out of place.
  • Confirm the bed is securely fixed before starting the print.
  • Warping in the upper layers causing the nozzle to hit solid parts of the print:
    • Maintain similar belt tension for all belts, avoiding excessive looseness.
    • Check and tighten the drive coupler(s).
    • Clean and lubricate the rods.
    • Inspect for deformed rods.

• Missing Layer (a form of under-extrusion):
  • Large filament diameter variation.
  • Tension on the filament spool.
  • Tension on the feeder gear.
  • (Partially) Clogged nozzle.
  • Rod alignment problems. If reproducible, Z-axis rods could be distorted, dirty, or suffering from excessive oil. (A noisy bearing is always a bad sign; in severe cases, the bearing may need replacement).
  • Ensure everything is sufficiently greased.

• Leaning Prints:
  • Usually due to belts slipping, often caused by a loose grub screw on a pulley, but sometimes belts can be rubbing.

• Overheating/Curling:
  • Check material settings.
  • Lower extrusion temperature.
  • Print faster.