Stringing or Oozing in 3D Printing

Stringing or Oozing

Stringing (otherwise known as oozing, whiskers, or “hairy” prints) occurs when small strings of plastic are left behind on a 3D printed model. This is typically due to plastic oozing out of the nozzle while the extruder is moving to a new location. Thankfully, there are several settings within Simplify3D that can help with this issue. The most common setting that is used to combat excessive stringing is something that is known as retraction. If retraction is enabled, when the extruder is done printing one section of your model, the filament will be pulled backwards into the nozzle to act as a countermeasure against oozing. When it is time to begin printing again, the filament will be pushed back into the nozzle so that plastic once again begins extruding from the tip. To ensure retraction is enabled, click “Edit Process Settings” and click on the Extruder tab. Ensure that the retraction option is enabled for each of your extruders. In the sections below, we will discuss the important retraction settings as well as several other settings that can be used to combat stringing, such as the extruder temperature settings.

Retraction distance

The most important retraction setting is the retraction distance. This determines how much plastic is pulled out of the nozzle. In general, the more plastic that is retracted from the nozzle, the less likely the nozzle is to ooze while moving. Most direct-drive extruders only require a retraction distance of 0.5-2.0mm, while some Bowden extruders may require a retraction distance as high as 15mm due to the longer distance between the extruder drive gear and the heated nozzle. If you encounter stringing with your prints, try increasing the retraction distance by 1mm and test again to see if the performance improves.

Retraction speed

The next retraction setting that you should check is the retraction speed. This determines how fast the filament is retracted from the nozzle. If you retract too slowly, the plastic will slowly ooze down through the nozzle and may start leaking before the extruder is done moving to its new destination. If you retract too quickly, the filament may separate from the hot plastic inside the nozzle, or the quick movement of the drive gear may even grind away pieces of your filament. There is usually a sweet spot somewhere between 1200-6000 mm/min (20-100 mm/s) where retraction performs best. Thankfully, Simplify3D has already provided many pre-configured profiles that can give you a starting point for what retraction speed works best, but the ideal value can vary depending on the material that you are using, so you may want to experiment to see if different speeds decrease the amount of stringing that you see.

Temperature is too high

Once you have checked your retraction settings, the next most common cause for excessive stringing is the extruder temperature. If the temperature is too high, the plastic inside the nozzle will become less viscous and will leak out of the nozzle much more easily. However, if the temperature is too low, the plastic will still be somewhat solid and will have difficulty extruding from the nozzle. If you feel you have the correct retraction settings, but you are still encountering these issues, try decreasing your extruder temperature by 5-10 degrees. This can have a significant impact on the final print quality. You can adjust these settings by clicking “Edit Process Settings” and selecting the Temperature tab. Select your extruder from the list on the left, and then double-click on the temperature setpoint you wish to edit.

Long movements over open spaces

As we discussed above, stringing occurs when the extruder is moving between two different locations, and during that move, plastic starts to ooze out of the nozzle. The length of this movement can have a large impact on how much oozing takes place. Short moves may be quick enough that the plastic does not have time to ooze out of the nozzle. However, long movements are much more likely to create strings. Thankfully, Simplify3D includes an extremely useful feature that can help minimize the length of these movements. The software is smart enough that it can automatically adjust the travel path to make sure that nozzle has a very short distance to travel over an open space. In fact, in many cases, the software may be able to find a travel path that avoids crossing an open space all together! This means that there is no possibility to create a string, because the nozzle will always be on top of the solid plastic and will never travel outside the part. To use this feature, click on the Advanced tab and enable the “Avoid crossing outline for travel movement” option.

Movement Speed

Finally, you may also find that increasing the movement speed of your machine can also reduce the amount of time that the extruder can ooze when moving between parts. You can verify what movement speeds your machine is using by clicking on the Speeds tab of your process settings. The X/Y Axis Movement Speed represents the side-to-side travel speed, and is frequently directly related to the amount of time your extruder spends moving over open air. If your machine can handle moving at higher speeds, you may find that increasing this settings can also reduce stringing between parts.

LAYER SHIFTING IN 3D PRINTING

Layer Shifting

Most 3D printers use an open-loop control system, which is a fancy way to say that they have no feedback about the actual location of the tool-head. The printer simply attempts to move the tool-head to a specific location, and hopes that it gets there. In most cases, this works fine because the stepper motors that drive the printer are quite powerful, and there are no significant loads to prevent the tool-head from moving. However, if something does go wrong, the printer would have no way to detect this. For example, if you happened to bump into your printer while it was printing, you might cause the tool-head to move to a new position. The machine has no feedback to detect this, so it would just keep printing as if nothing had happened. If you notice misaligned layers in your print, it is usually due to one of the causes below. Unfortunately, once these errors occur, the printer has no way to detect and fix the problem, so we will explain how to resolve these issues below.

Common Solutions

Tool-head is moving too fast

If you are printing at a very high speed, the motors for your 3D printer may struggle to keep up. If you attempt to move the printer faster than the motors can handle, you will typically hear a clicking sound as the motor fails to achieve the desired position. If this happens, the remainder of the print will be misaligned with everything that was printed before it. If you feel that your printer may be moving too fast, try to reduce the printing speed by 50% to see if it helps. To do this, click “Edit Process Settings” and select the Speeds tab. Adjust both the “Default Printing Speed” and the “X/Y Axis Movement Speed.” The default printing speed controls the speed of any movements where the extruder is actively extruding plastic. The X/Y axis movement speed controls the speed of rapid movements where no plastic is being extruded. If either of those speeds are too high, it can cause shifting to occur. If you are comfortable adjusting more advanced settings, you may also want to consider lowering the acceleration settings in your printer’s firmware to provide a more gradual speed up and slow down.

Mechanical or Electrical Issues

If the layer misalignment continues, even after reducing your print speed, then it is likely due to mechanical or electrical issues with the printer. For example, most 3D printers use belts that allow the motors to control the position of the tool-head. The belts are typically made of a rubber material and reinforced with some type of fiber to provide additional strength. Over time, these belts may stretch, which can impact the belt tension that is used to position the toolhead. If the tension becomes too loose, the belt may slip on top of the drive pulley, which means the pulley is rotating, but the belt is not moving. If the belt was originally installed too tight, this can also cause issues. An over-tightened belt can create excess friction in the bearings that will prevent the motors from spinning. Ideal assembly requires a belt that is somewhat tight to prevent slipping, but not too tight to where the system is unable to rotate. If you start noticing issues with misaligned layers, you should verify that your belts all have the appropriate tension, and none appear to be too loose or too tight. If you think there may be a problem, please consult the printer manufacturer for instructions on how to adjust the belt tension.

Many 3D printers also include a series of belts that are driven by pulleys attached to a stepper motor shaft using a small set-screw (otherwise known as a grub screw). These set-screws anchor the pulley to the shaft of the motor so that the two items spin together. However, if the set-screw loosens, the pulley will no longer rotate together with the motor shaft. This means that the motor may be spinning, but the pulley and belts are not moving. When this happens, the toolhead does not get to the desired location, which can impact the alignment of all future layers of the print. So if layer misalignment is a reoccurring problem, you should verify that all of the motor fasteners are properly tightened.

There are also several other common electrical issues that can cause the motors to lose their position. For example, if there is not enough electrical current getting to the motors, they won’t have enough power to spin. It is also possible that the motor driver electronics could overheat, which causes the motors to stop spinning temporarily until the electronics cool down. While this is not an exhaustive list, it provides a few ideas for common electrical and mechanical causes that you may want to check if layer shifting is a persistent problem.

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Invitation | Come and experience magic at the 3D PRINT EXPO 2018 | 6th and 7th August 2018, Pragati Maidan | TecnisiaCAD

Greetings from TecnisiaCAD!

You are most welcome to come and see what is new in the realm of 3D Printing at the 3D PRINT EXPO 2018 on 6th and 7th August, 2018. 

We will display a range of cost-effective and efficient 3D Printers from Flashforge, Creality and Original Prusa as well as a variety of magnificent 3D Printed Samples. We will help you with ways to transform your business with the assistance of a 3D Printer. 

If there are any other queries, please feel free to contact me. 

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Significance of Meshing in Analysis

MESHING IN ANALYSIS

Finite Element Analysis (FEA) provides a reliable numerical technique for analyzing engineering designs. The process starts with the creation of a geometric model. Then, the program subdivides the model into small pieces of simple shapes (elements) connected at common points (nodes). Finite element analysis programs look at the model as a network of discrete interconnected elements.

The Finite Element Method (FEM) predicts the behavior of the model by combining the information obtained from all elements making up the model.

Meshing is a very crucial step in design analysis. The automatic mesher in the software generates a mesh based on a global element size, tolerance, and local mesh control specifications. Mesh control lets you specify different sizes of elements for components, faces, edges, and vertices.

The software estimates a global element size for the model taking into consideration its volume, surface area, and other geometric details. The size of the generated mesh (number of nodes and elements) depends on the geometry and dimensions of the model, element size, mesh tolerance, mesh control, and contact specifications. In the early stages of design analysis where approximate results may suffice, you can specify a larger element size for a faster solution. For a more accurate solution, a smaller element size may be required.

Meshing generates 3D tetrahedral solid elements, 2D triangular shell elements, and 1D beam elements. A mesh consists of one type of elements unless the mixed mesh type is specified. Solid elements are naturally suitable for bulky models. Shell elements are naturally suitable for modeling thin parts (sheet metals), and beams and trusses are suitable for modeling structural members.

Solid Mesh

In meshing a part or an assembly with solid elements, the software generates one of the following types of elements based on the active mesh options for the study:

Draft quality mesh	The automatic mesher generates linear tetrahedral solid elements.
High quality mesh	The automatic mesher generates parabolic tetrahedral solid elements.

Linear elements are also called first-order, or lower-order elements. Parabolic elements are also called second-order, or higher-order elements.

A linear tetrahedral element is defined by four corner nodes connected by six straight edges. A parabolic tetrahedral element is defined by four corner nodes, six mid-side nodes, and six edges. The following figures show schematic drawings of linear and parabolic tetrahedral solid elements.

In general, for the same mesh density (number of elements), parabolic elements yield better results than linear elements because: 1) they represent curved boundaries more accurately, and 2) they produce better mathematical approximations. However, parabolic elements require greater computational resources than linear elements.

For structural problems, each node in a solid element has three degrees of freedom that represent the translations in three orthogonal directions. The software uses the X, Y, and Z directions of the global Cartesian coordinate system in formulating the problem.

For thermal problems, each node has one degree of freedom which is the temperature.

Shell Mesh

When using shell elements, the software generates one of the following types of elements depending on the active meshing options for the study:

Draft quality mesh	The automatic mesher generates linear triangular shell elements.
High quality mesh	The automatic mesher generates parabolic triangular shell elements.

A linear triangular shell element is defined by three corner nodes connected by three straight edges. A parabolic triangular element is defined by three corner nodes, three mid-side nodes, and three parabolic edges. For studies using sheet metals, the thickness of the shells is automatically extracted from the geometry of the model.

To set the desired option for a study, right-click the Mesh icon, select Create Mesh, and expand Advanced.

Shell elements are 2D elements capable of resisting membrane and bending loads.

Linear triangular element

Parabolic triangular element

For structural studies, each node in shell elements has six degrees of freedom; three translations and three rotations. The translational degrees of freedom are motions in the global X, Y, and Z directions. The rotational degrees of freedom are rotations about the global X, Y, and Z axes.

For thermal problems, each node has one degree of freedom which is the temperature.

The software generates a shell mesh automatically for the following geometries:

Sheet metals with uniform thicknesses	Sheet metals mesh with shell elements, except for drop test studies. The software assigns the thickness of shell based on sheet metal thickness. You can edit the default shell definition before running the study, except thickness.
Surface bodies	Surface bodies mesh with shell elements. The software assigns a thin shell formulation to each surface body. You can edit the default shell definition before running the study. For Engineering Tutorials: https://www.youtube.com/TecnisiaCAD http://tecnisiacadtraining.business.site Information Courtesy: SolidWorks Simulation

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We at TecnisiaCAD are responsible for providing CADCAMCAE technologies that leverages Industrial business processes. We offer 6 weeks summer training in CAD for students which is a fully job oriented project based training that enables students to work on Live design projects from the industry. We provide AutoCAD certification training in Delhi, for students as well as for working professionals.

We are providing Best CAD course in delhi that can be a turning point for all the students who has undergone B.tech ME or Civil, Diploma in ME or Civil course and many more. In this age of computers and technology it's nearly impossible to get JOBS with just degrees or diplomas. One must be able to understand and have deep knowledge in at least one of the relevant technologies. For students to develop the skills as required by the industry. TecnisiaCAD provides the best CAD training in delhi with fully equipped labs and enriched project and exercise workbooks.

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