Warping or deformation of 3D printed objects is a common post-processing challenge, which is usually related to material contraction, printing environment, and printing parameter settings. The following are possible causes and solutions based on different types of 3D printers.
Fused Deposition Modeling (FDM)
Possible reasons:
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Printing temperature is too high or too low, resulting in uneven material contraction.
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The printing speed is too fast, resulting in insufficient material cooling.
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Insufficient adhesion between printing layers.
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Improper printing platform temperature affects the adhesion of the bottom surface.
Solution:
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Adjust the printing temperature to the recommended range for the material.
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Reduce printing speed and increase Cool Down.
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Optimize inter-layer bonding with appropriate layer height and print path.
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Adjust the printing platform temperature to ensure good adhesion of the first layer.
Stereolithography (SLA)
Possible reasons:
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Exposure time is too long or too short, resulting in uneven resin curing.
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The construction platform is not level, which affects the flatness of the layer.
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Improper management of resin liquid level in resin tank.
Solution:
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Adjust the exposure time to the recommended range of resin.
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Calibrate the build platform to ensure its level.
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Manage the liquid level in the resin tank to ensure uniform resin filling.
Digital Light Processing (DLP)
Possible reasons:
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Exposure time is too long or too short, resulting in uneven resin curing.
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The uneven resin level affects the curing depth.
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The printing platform is not level.
Solution:
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Adjust the exposure time to the recommended range of resin.
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Use a scraper to ensure even resin level.
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Calibrate the printing platform to ensure its level.
Selective Laser Sintering (SLS)
Possible reasons:
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Uneven laser power leads to uneven powder sintering.
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Improper printing parameter settings, such as scanning speed being too fast.
Solution:
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Check the laser power to ensure uniform distribution.
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Adjust print parameters, such as reducing scan speed.
Powder Bed Fusion (PBF)
Possible reasons:
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The laser beam is not focused accurately, resulting in uneven melting.
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Improper printing parameter settings, such as laser scanning speed being too fast.
Solution:
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Check laser beam focus and calibrate if necessary.
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Adjust printing parameters, such as reducing laser scanning speed.
General solution:
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Using support structures: For complex geometries, using support structures can help reduce warping.
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Post-processing: For warped objects, the shape can be corrected by heating and pressing.
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Environmental control: Control the temperature and humidity of the printing environment to reduce the warping of materials caused by environmental changes.
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Material selection: Choose the appropriate printing material, some materials are more resistant to warping.
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Printing direction: Adjust the printing direction so that the printing direction is perpendicular to the maximum area of the object, reducing warping.
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Cooling system: Use an appropriate cooling system to ensure uniform cooling of the material.
For different types of 3D printers, solving warping or deformation problems requires a deep understanding of the printer’s working principle and adjusting and optimizing according to specific situations. Regular maintenance and calibration are also key to ensuring print quality.
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