prusa3d / PrusaSlicer

G-code generator for 3D printers (RepRap, Makerbot, Ultimaker etc.)
https://www.prusa3d.com/prusaslicer/
GNU Affero General Public License v3.0
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Long Skinny Sections come out weak due to Automatic extrusion width calculation flaws. #1855

Open Isaak-Malers opened 5 years ago

Isaak-Malers commented 5 years ago

Version

1.41

Operating system type + version

N/A

3D printer brand / version + firmware version (if known)

Custom Delta Kossel Duplicator 6 Maker Select Plus FT-5 N/A * all printers exhibit this issue.

Behavior

Slic3r performs very poorly in printing long runs of a part that are barely too thin to require infill. This kind of model is extremely common when trying to use a 3d print to emulate an injection molded part. To reproduce issue, print the linked part with the following conditions:

Test STL: printer-test.zip

Results: Perimeters do not bond together, and it is possible to "splinter" the print apart. Depending on how many perimeters there are. Note that this is not an issue with under-extrusion or printer "slop" 2/4 of the walls on this print come out great for me, and the results are the same regardless of orientation of the part.

inkedtest print alloy 910_li

Expected Results: The part shouldn't be so weak. But more specifically I could see this being solved in 2 ways:

  1. More sophisticated extrusion width/flow rate calculation, filling in the area with solid plastic.

  2. Instead of printing a part with all the requested perimeters, reduce the number of perimeters and print the "inner perimeters" as solid infill instead.

bubnikv commented 5 years ago

This sounds like an under-extrusion issue, and you need to calibrate your extruder e-steps.

Instead of printing a part with all the requested perimeters, reduce the number of perimeters and print the "inner perimeters" as solid infill instead.

Do you have "Detect thin walls" enabled?

On Fri, Feb 22, 2019 at 9:23 AM isaakMalers notifications@github.com wrote:

Version

1.41 Operating system type + version

N/A 3D printer brand / version + firmware version (if known)

Custom Delta Kossel Duplicator 6 Maker Select Plus FT-5 N/A * all printers exhibit this issue. Behavior

Slic3r performs very poorly in printing long runs of a part that are barely too thin to require infill. This kind of model is extremely common when trying to use a 3d print to emulate an injection molded part. To reproduce issue, print the linked part with the following conditions:

  • .4mm nozzle
  • 3 perimeters
  • Nylon, Cheap ABS, Or any other "tricky because its prone to under-extrude" filament. Note that this kind of filament is not a requirement for this issue (given certain parts i can replicate with PLA), but it does make it easier to reproduce.
  • Slicer settings on default (1 print)
  • Slicer settings on default, but with .5mm extrusion widths over-ridden for everything. (1 print)

Test STL: printer-test.zip https://github.com/prusa3d/Slic3r-settings/files/2892959/printer-test.zip

Results: Perimeters do not bond together, and it is possible to "splinter" the print apart. Depending on how many perimeters there are. Note that this is not an issue with under-extrusion or printer "slop" 2/4 of the walls on this print come out great for me, and the results are the same regardless of orientation of the part.

[image: inkedtest print alloy 910_li] https://user-images.githubusercontent.com/8919579/53228439-74629200-363e-11e9-86ce-d79dcf52f821.jpg

Expected Results: The part shouldn't be so weak. But more specifically I could see this being solved in 2 ways:

1.

More sophisticated extrusion width/flow rate calculation, filling in the area with solid plastic. 2.

Instead of printing a part with all the requested perimeters, reduce the number of perimeters and print the "inner perimeters" as solid infill instead.

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Isaak-Malers commented 5 years ago

I've noted this problem on 5+ printers, all before and after estep calibration. In the STL i linked certain parts of the model will print poorly and other will print well. A hardware issue wouldn't come and go so reliably depending on wall thickness.

I do have "Detect thin walls" enabled, but I don't think that is relevant. The thinnest wall on my test print is 1.5mm across. My understanding is that Thin Walls are walls less than a single extrusion width.

Isaak-Malers commented 5 years ago

Upon further investigation, this appears to be an issue caused by the fact that different fillaments have different cross section shapes after extrusion. A good fix would be allowing setting the extrusion multiplier individually for each of the extrusion width types. Infill, first layer, perimiters, etc. A more complex solution might be allowing users to tune the extrusion shape function.

Then for the "interior perimiters" I can set an extrusion multiplier that will fix my gapfill issue without un-calibrating the rest of my print.