While one of the easiest materials to 3D print, PLA is not known for its high temperature resistance.

The most popular 3D printing filament, PLA is known for many things, like its good printability and ability to withstand warping. When it comes to temperature resistance, however, the material has its limitations. In this article, we're diving into PLA's thermal properties and comparing them to other common filaments.

How PLA Temperature Resistance Compares to Other 3D Printing Materials

<section data-loopindex="1" data-theme="light" id="isPasted"><div data-loopindex="1"><p dir="ltr">Slicing software has been around since the very beginning of 3D printing, with digital slicing of STL files being one of the key features of Chuck Hull&rsquo;s first stereolithography system. However, in the time since, slicing software has evolved beyond its base functions of simply converting 3D object models into machine instructions.</p><p dir="ltr">Today, enterprise-scale software platforms like Eiger not only provide slicing&mdash; they serve as an organization&rsquo;s digital hub for&nbsp;<a href="https://markforged.com/resources/blog/additive-manufacturing-101-guide-the-basics" target="_blank">additive manufacturing</a> activities such as managing printer fleets, digital inventories of parts, and accessing usage analytics.</p><p dir="ltr">Also, new&nbsp;<a href="https://markforged.com/software" target="_blank">3D printing software</a> tools now exist to further streamline and automate additive manufacturing operations, which can save organizations large amounts of time and money while making life easier.</p><p dir="ltr">Curious to learn about today&rsquo;s available 3D printing software? Read this article for an introduction.</p></div></section><section data-loopindex="2" data-theme="light"><div data-loopindex="2"><h3></h3><h2 dir="ltr"><strong>Slicing software: more than just print settings</strong></h2><p dir="ltr">A slicing program transforms a digital model into a set of instructions that the 3D printer can use to produce a tangible part. It takes a&nbsp;<a href="https://markforged.com/resources/blog/how-to-create-high-quality-stl-files-for-3d-prints" target="_blank">3D model</a>, &lsquo;slices&rsquo; it into the many distinct horizontal layers that together comprise a 3D-printed part, while customizing print settings and generating toolpaths &mdash; converting all of this information into machine-readable instructions for the printer to follow. Slicers allow users to define key parameters for each print &mdash; such as print orientations, layer heights, support structures, print speeds, infill densities, continuous fiber reinforcement, and other settings.</p><p dir="ltr">Certain modern slicing software programs, such as Eiger, also serve as an organization&rsquo;s digital hub for managing nearly all 3D printing activities. Along with base slicing functions, cloud-based applications like&nbsp;<a href="https://markforged.com/management-integration" target="_blank">Eiger</a> have features for managing part files, multiple printers, simultaneous print jobs, and users within an organization (through role-based access control), as well as tracking performance and usage analytics.</p><p dir="ltr">With many global manufacturers using 3D printing for core operations, Markforged designed Eiger software to be a simple means for managing print jobs across printers in different geographic locations &mdash; making this also a powerful supply chain tool for fast, on-demand procurement of parts. Storing parts in the cloud as digital inventories also allows manufacturers to avoid allocating valuable space for physical inventories of spare parts.</p><p dir="ltr"><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe width="640" height="360" src="https://www.youtube.com/embed/FfN9-Z9egCw?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><em>How can we extend the benefits of 3D printed parts to worksites across the globe? Being able to 3D print parts at the point of need makes operations more agile, efficient, and cost-effective.&nbsp;</em></p><section data-loopindex="4" data-theme="light" id="isPasted"><div data-loopindex="4"><h3></h3><h2 dir="ltr"><strong>API integrations: automate workflows between 3D printing, factory systems</strong></h2><p dir="ltr">Through API integrations, different factory systems (like ERP or MES systems) can speak to each other, syncing data. Integration offers&nbsp;<a href="https://markforged.com/resources/blog/why-integrate-factory-systems-with-3d-printing-software#:~:text=Benefits%20of%203D%20printing%20software%20integration" target="_blank">a number of benefits</a>. Successful integrations, through automating processes and information transfer, ultimately save time, reduce errors, and reduce delays that take place between actions.</p><p dir="ltr">Through an API integration, slicing software like Eiger can be integrated with other factory systems, automating additive-related workflows at other digital manufacturing touchpoints. Other important business systems can automatically receive details from the slicer around their parts, builds, print jobs, and printers. For example, a slicer can automatically prompt an asset management system to track each printed part &mdash; or automatically prompt a Digital Kanban Inventory system to initiate a print when inventory falls beneath a defined threshold.</p><p dir="ltr">Through API integrations, slicers can connect with many different factory systems: a Manufacturing Execution System (MES), Product Lifecycle Management (PLM) system, or Enterprise Resource Planning (ERP) system, QMS, CRM, AM/EAM, SCM, financials, accounting systems, and more.</p></div></section><section data-loopindex="5" data-theme="light"><div data-loopindex="5"><h3></h3><h2 dir="ltr"><strong>Simulating part performance: determining strength and stiffness before hitting &lsquo;print&rsquo;</strong></h2><p dir="ltr">For many 3D printed parts &mdash; from tooling built for factory floors, to&nbsp;<a href="https://markforged.com/resources/blog/3-ways-to-deliver-trusted-parts-faster-with-simulation" target="_blank">composite steering wheels</a> guiding drag racing vehicles that reach speeds of 275+ mph &mdash; high strength and stiffness are absolutely crucial. Furthermore, as many organizations operate on development and production cycles with limited time, it&rsquo;s valuable to know that your part meets its performance requirements without having to print and break the design many times.</p><p dir="ltr"><a href="https://markforged.com/simulation" target="_blank">3D printing simulation software</a> allows organizations to virtually test part strength and stiffness, where users can validate how their part will perform&nbsp;<strong>before&nbsp;</strong>they print it. Simulation software dramatically reduces the need for print-break test cycles, which typically consume significant amounts of time and material. 3D printing simulation software can also optimize prints to reduce material costs and/or print times, while still meeting defined performance requirements.</p><p dir="ltr">Simulation software works by using information about strength and stiffness requirements, the use case, and the part itself. After the user specifies and inputs the necessary testing criteria and performance factors, the software runs its simulation to determine if the part passes or fails the virtual performance test.</p><p dir="ltr"><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe width="640" height="360" src="https://www.youtube.com/embed/20eHQzZ-FGQ?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><em>Learn how simulating part performance can help cut print times, increase part stiffness, all while maintaining strength and cost.&nbsp;</em></p><section data-loopindex="7" data-theme="light" id="isPasted"><div data-loopindex="7"><h3></h3><h2 dir="ltr"><strong>In-process quality inspection</strong></h2><p dir="ltr">Given the requisite hardware and software, certain 3D printers can scan parts for quality assurance inspection during the printing process. Once printing is finished, the inspection software automatically generates a report that shows you if your part is within spec via clear pass/fail analysis.</p><p dir="ltr"><a href="https://markforged.com/inspection" target="_blank">3D printing inspection software</a> works by using an onboard laser micrometer and a scanning process. It generates a laser inspection toolpath at slicing time for your part and build settings. When the part begins printing, the software automates the collection, upload, and registration of measurement data to help users ascertain if each part printed is within the acceptable tolerance.</p><p dir="ltr">Ultimately, automated inspection of parts boosts manufacturing productivity by reducing manpower and time required for manual quality assurance.</p></div></section><section data-loopindex="8" data-theme="light"><div data-loopindex="8"><h3></h3><h2><strong>Is 3D printing software secure?</strong></h2><p dir="ltr">A single cybersecurity breach can be incredibly costly for any business hit. With organizations now storing sensitive data in the cloud, information security has topical importance in&nbsp;<a href="https://markforged.com/3d-printers" target="_blank">industrial 3D printing</a> &mdash; after all, when storing proprietary parts in the cloud as digital inventory, manufacturers need to protect their intellectual property.</p><p dir="ltr">The Digital Forge, including Eiger software, is the first additive manufacturing platform to attain<strong>&nbsp;ISO/IEC 27001</strong> certification, meeting rigorous international standards for data management and information security.</p><p dir="ltr"><span class="fr-video fr-deletable fr-fvc fr-dvb fr-draggable" contenteditable="false" draggable="true"><iframe width="640" height="360" src="https://www.youtube.com/embed/r_wczXR9sSI?&wmode=opaque&rel=0&enablejsapi=1&origin=https://www.wevolver.com" frameborder="0" allowfullscreen="" class="fr-draggable" data-lf-form-tracking-inspected-kn9eq4roawkarlvp="true" data-lf-yt-playback-inspected-kn9eq4roawkarlvp="true" data-lf-vimeo-playback-inspected-kn9eq4roawkarlvp="true"></iframe></span><em>How does Markforged secure your data? </em></p><section data-loopindex="10" data-theme="light" id="isPasted"><div data-loopindex="10"><p dir="ltr">Markforged 3D printing software uses&nbsp;<strong>SAML SSO</strong> (single sign-on) and&nbsp;<strong>TLS</strong> (transport layer security) certificates. SAML SSO provides a simplified authentication process across enterprise applications with the benefit of improved security. As only one set of credentials is needed per user, user credentials for the organization do not need to be stored in any system. TLS certificates ensure critical information passed from web applications is securely encrypted &mdash; to prevent unwanted modifications, loss, or theft of important data.</p><p><strong>RBAC&nbsp;</strong>(role-based access control) in Markforged 3D printing software offers additional benefits for data management and information security. Ensuring employees only have access to the information they need improves confidentiality, privacy, and compliance. RBAC protects sensitive data from unwanted access, modification, leaks, or deletion &mdash; while also simplifying organizational user management processes.</p></div></section><section data-loopindex="11" data-theme="light"><div data-loopindex="11"><h3></h3><h2 dir="ltr"><strong>3D printing software has evolved substantially. What&rsquo;s next?</strong></h2><p dir="ltr">3D printing software has come a long way since back when it was introduced to serve a single purpose.</p><p dir="ltr">Today, innovative slicing applications like Eiger have expanded how 3D printing software can create value for manufacturers beyond just the domain of slicing, evolving into a new industry benchmark: enterprise-grade control centers for additive manufacturing operations. This modern 3D printing software has created new ways for 3D printers to manage inventory, solve supply chain problems, and easily manage all 3D printing operations.</p><p dir="ltr">As more manufacturers digitally transform to make operations leaner and more efficient, the role of industrial 3D printing continues to grow. Today&rsquo;s cutting edge software tools &mdash; such as performance simulation, slicing APIs, and in-process inspection &mdash; continue to make industrial 3D printing an even faster, more efficient, and more automated solution for solving the biggest challenges in manufacturing.</p></div></section></div></section></div></section></div></section>

Slicing software has been around since the very beginning of 3D printing, with digital slicing of STL files being one of the key features of Chuck Hull’s first stereolithography system. However, in the time since, slicing software has evolved beyond its base functions of simply converting 3D object models into machine instructions.

From Slicers to Performance Simulators: Evolution of Industrial 3D Printing Software

<p dir="ltr" id="isPasted"><span style="background-color: transparent;">3D printing, also known as additive manufacturing, revolutionizes the way we create objects. This technology allows us to fabricate complex shapes and structures that would be difficult or impossible with traditional manufacturing methods.</span></p><p dir="ltr">However, like any technology, it comes with its unique challenges. Among them is a phenomenon called &quot;elephant foot.&quot; The 3D printing elephant foot issue, common especially among beginners, can significantly impact the quality of the final print. By understanding the 3D printing elephant foot phenomenon and the strategies to mitigate it, you can greatly enhance the precision and aesthetics of your 3D printed parts.</p><p dir="ltr">This guide explains how to recognize 3D printing elephant foot, lists&nbsp;the main causes of it, and explains how to fix it.</p><h1 dir="ltr">The Elephant Foot Phenomenon in 3D Printing</h1><p dir="ltr">The term &quot;elephant foot&quot; refers to a specific type of distortion commonly observed in 3D printed objects. This phenomenon typically manifests as an outward flaring or bulging at the base of a printed part, which visually resembles the foot of an elephant, hence the name. This distortion can be as small as a few hundred microns, but in severe cases, it can extend several millimeters beyond the intended dimensions of the part.</p><p dir="ltr">The occurrence of elephant foot is closely linked to the physics of the 3D printing process itself. During printing, each layer of material is heated and then rapidly cooled to solidify it. The first few layers, being closest to the heated print bed, remain warm for longer periods, leading to an extended period of plasticity. This extended plasticity, combined with the weight of the subsequent layers, results in the base layers spreading outwards, creating the characteristic bulge of elephant foot.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/3d-print-ghosting-causes-and-potential-solutions" target="_blank"><em>3D print ghosting causes and potential solutions</em></a></strong></p><h1 dir="ltr">Causes of Elephant Foot</h1><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686229982818-3d_printing.jpg" style="width: 300px;" class="fr-fic fr-dib" alt="elephant foot"><span class="fr-inner">Elephant foot is usually easy to spot</span></span></span></p><p dir="ltr">A number of factors can contribute to elephant foot. One is the elevated temperature of the print bed, which is often necessary to keep the initial layers of the print adhered to the build platform.[1] High bed temperatures, typically in the range of 60 to 110 &deg;C depending on the material, keep the bottom layers in a semi-melted state for an extended period. As more layers are added, they exert pressure on the base layers, causing them to spread out, resulting in elephant foot. Inadequate cooling from the printer&rsquo;s fan can worsen the effect.</p><p dir="ltr">Bed leveling inaccuracies can also exacerbate the 3D printing elephant foot issue. If the distance between the nozzle and the bed is too small, the first layer of the print is squished onto the bed more than intended. This excessive squishing can cause the material to spread outward beyond the intended footprint, contributing to elephant foot. The issue can be more pronounced in printers with manual bed leveling due to the potential for human error.</p><p dir="ltr">Other potential factors that can contribute to elephant foot include environmental factors, the design of the object being printed, and high infill densities. High infill can produce more internal stress in a part as it cools and shrinks, which can push the bottom layers outwards. This is especially true if the infill cools at a different rate than the outer walls, creating a thermal gradient that leads to uneven shrinkage.</p><h1 dir="ltr">Implications of Elephant Foot</h1><p dir="ltr">The elephant foot phenomenon has several critical implications for 3D printing, affecting both aesthetics and functionality. In terms of aesthetics, the outward spread at the base disrupts the intended design, leading to a distorted profile. This distortion can be particularly problematic for prints intended to be visually accurate models or prototypes, where precision is of utmost importance.</p><p dir="ltr">Functional implications arise when the 3D printed object is meant to fit into an existing assembly or when multiple parts of a model need to fit together. The outward bulge at the base of the printed object can affect tolerance, causing the part to be larger than intended and preventing it from fitting properly. For example, in the case of a socket and plug design, the plug might not fit into the socket if the base of the plug has an elephant foot. Similarly, a part designed to slot into a specific space may not fit if the base is larger than anticipated.</p><p dir="ltr">The structural integrity of the printed object can also be compromised. The bottom layers in a print with an elephant foot are generally more stressed due to the spreading, which can lead to weaknesses. The print may be more likely to crack or break along these lines of stress, especially under load or impact.</p><h1 dir="ltr">Troubleshooting Elephant Foot</h1><p dir="ltr">Given the implications of the elephant foot phenomenon, it is crucial to know how to mitigate or entirely fix elephant foot in 3D printing projects. Here we will explore several troubleshooting techniques, including calibration, design choices, and slicer settings.</p><h2 dir="ltr">Calibration</h2><p dir="ltr">Proper calibration of the 3D printer is a vital step in preventing the elephant foot phenomenon, with bed leveling and nozzle height the most important elements to consider.</p><h3 dir="ltr">Bed Leveling</h3><p dir="ltr">The build plate&#39;s alignment and levelness are fundamental to the quality of the first layer and, by extension, the entire print. A build plate that is too close to the nozzle during the first layer&#39;s printing can cause the extruded filament to spread out more than intended, leading to the elephant foot effect.</p><p dir="ltr">To calibrate the build plate, start by heating it to the usual printing temperature to account for thermal expansion, a factor that can slightly alter the plate&#39;s levelness. Use a piece of paper or a feeler gauge to adjust the distance between the build plate and the nozzle. The paper or gauge should slide between the two with a small amount of resistance. Repeat this process at several points across the build plate to ensure uniform levelness.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/ender-3-pro-bed-leveling-a-comprehensive-guide" target="_blank"><em>Ender 3 Pro Bed Leveling: A Comprehensive Guide</em></a></strong></p><h3 dir="ltr">Z-axis Adjustment</h3><p dir="ltr">Another hardware issue that can cause elephant foot is the Z-axis. Users of Creality Ender 3 printers in particular have found that the issue is sometimes caused by excessive tightness of the eccentric nuts for the wheels of the Z-axis. Loosening these nuts can help reduce elephant foot.</p><p dir="ltr">Additionally, loosening the two screws holding the large Z-axis screw to the X-axis carriage can help with the issue.</p><h2 dir="ltr">Design Adjustments</h2><h3 dir="ltr">Chamfers</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTU2NDk3ODgyLWNoYW1mZXItbWl0ZXIucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 300px;" class="fr-fic fr-dib" alt="chamfers"><span class="fr-inner">Chamfers can be added using applications like Fusion 360 (credit: Autodesk)</span></span></span></p><p dir="ltr">Adding a chamfer &mdash; a sloping edge &mdash; to your CAD 3D model is one way to combat 3D printing elephant foot. Most design software applications allow for easy implementation of chamfers to existing surfaces.</p><p dir="ltr">A chamfer can mitigate the effect of elephant foot because it makes each of the first few layers slightly smaller than the next, effectively offsetting the spread of elephant foot. The size of the chamfer can also be precisely adjusted, allowing users to incorporate small chamfers for minor instances of elephant foot and wider chamfers for more severe cases.</p><h2 dir="ltr">Slicer Settings</h2><h3 dir="ltr">Bed Temperature</h3><p dir="ltr">The temperature of the heated bed can play an important role in preventing elephant foot. Although a heated bed helps with first-layer adhesion, it can also result in insufficient cooling, causing the first layers of the print to remain soft for too long and allowing them to spread out under the weight of subsequent layers. Reducing the print bed temperature can therefore reduce the effect of elephant foot.</p><p dir="ltr">Consider the recommended temperature range for the given filament and use a temperature at the lower end of this range. If this causes adhesion issues, try to address those issues via other means, such as adding an adhesive substance like glue to the bed surface.&nbsp;</p><h3 dir="ltr">First Layer Settings</h3><p dir="ltr">The various slicer settings for the first layer are crucial when combating elephant foot. The first layer height should be set to approximately 100% of the nozzle diameter. A lower value can cause the filament to spread out and form an elephant foot.</p><p dir="ltr">The first layer speed should be slower than the rest of the print. A speed of about 50% of the normal print speed is recommended.[2] Printing the first layer slowly allows the filament more time to adhere correctly to the build plate and cool down, reducing the chances of it spreading out.</p><p dir="ltr">The first layer extrusion rate, which controls how much filament is extruded, can also impact the elephant foot phenomenon. If too much filament is extruded, it may spread out and cause an elephant foot. An extrusion rate of about 95% to 100% of the standard rate is typically sufficient for the first layer.</p><p dir="ltr">The first layer fan speed can also help prevent elephant foot, as cooling helps the first layers solidify faster. However, as with lowering the bed temperature, this can have the negative effect of reducing bed adhesion, so consider implementing other techniques like build surface preparation to maintain good adhesion.</p><h3 dir="ltr">Expansion Compensation</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTU2NTU5Mjc0LWN1cmEuanBlZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 300px;" class="fr-fic fr-dib" alt="expansion compensation"><span class="fr-inner">Expansion compensation is a feature of Cura (credit: Ultimaker)</span></span></span></p><p dir="ltr">Most slicers offer a printer setting that is specifically designed to offset the effect of elephant&rsquo;s foot. In Cura, this setting is called &ldquo;initial layer horizontal expansion&rdquo; and is found under wall settings. The setting has different names in different slicers:</p><ul><li dir="ltr"><p dir="ltr">Cura: Initial Layer Horizontal Expansion</p></li><li dir="ltr"><p dir="ltr">Slic3r: Elephant Foot Compensation</p></li><li dir="ltr"><p dir="ltr">PrusaSlicer: Elephant Foot Compensation</p></li><li dir="ltr"><p dir="ltr">Simplify3D: Horizontal Side Compensation (must be tuned to first layer only)</p></li></ul><p dir="ltr">The function of this setting is to compensate for the deformation of printed plastic in the first layer. To reduce elephant&rsquo;s foot, a negative value should be input, as this will effectively decrease the XY dimensions of the first layer. Measure the distance of your existing elephant foot. If it is 0.1 mm, use a value of -0.1 mm for the expansion compensation parameter.</p><h3 dir="ltr">Rafts</h3><p dir="ltr">A raft is an extra layer of material that is printed underneath the object, effectively serving as a platform, that is later removed from the print and discarded. Using a raft means the negative effects of elephant foot are applied to the raft, rather than the print itself. However, rafts require extra material and therefore increase the cost of the print.</p><p dir="ltr">When setting up a raft, users should be mindful of the air gap between the raft and the model, which is typically between 0.1 mm and 0.3 mm. This gap allows the raft to be easily removed after printing while still providing the necessary support. For the raft layers, a 0.3 mm layer height is often used, as it provides a good balance between print time and quality.</p><h2 dir="ltr">Environment</h2><h3 dir="ltr">Ambient Temperature</h3><p dir="ltr">The ambient temperature around the printer can affect the cooling rate of the extruded filament. A higher ambient temperature might slow down the cooling rate, causing the base layers to remain soft for longer. This softened state allows the weight of the upper layers to push down on the base layers, leading to the elephant foot effect.</p><p dir="ltr">Ideally, the ambient temperature should be stable and within a range that allows the filament to cool sufficiently without solidifying too quickly. For example, PLA prints well at an ambient temperature of 20-25&deg;C, whereas ABS might require a slightly higher temperature due to its higher melting point. This range varies with the type of filament material used.</p><h3 dir="ltr">Airflow</h3><p dir="ltr">Airflow around the 3D printer can also influence the cooling rate of the filament. It is therefore important to maintain a controlled and steady airflow around the printer. This can be achieved through careful placement of the 3D printer and the use of enclosures for printers that do not have built-in covers.</p><h2 dir="ltr">Post-Processing Techniques</h2><h3 dir="ltr">Sanding</h3><p><span class="fr-img-caption fr-fic fr-dib" style="width: 302px;"><span class="fr-img-wrap"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1686230110460-abrasive_sandpaper.jpg" style="width: 300px;" class="fr-fic fr-dib" alt="sanding"><span class="fr-inner">Sanding can be used to manually remove elephant foot</span></span></span></p><p dir="ltr">One of the most common post-processing techniques is sanding, which can effectively reduce the prominence of elephant foot on a printed object. Sanding involves the use of sandpaper or other abrasive materials to smooth out the uneven bottom layers of the print. For best results, start with a lower grit (rougher) sandpaper, such as 100 grit, to remove the bulk of the elephant foot. Then, progressively move to higher grit (finer) sandpapers, such as 400 and then 800, to refine the surface and achieve a smooth finish.</p><h3 dir="ltr">Filing</h3><p dir="ltr">A file can be used for a more aggressive removal of the elephant foot, especially for larger prints or those made from tougher materials. When filing, it&#39;s essential to maintain a consistent angle and pressure to avoid creating new deformities. Files come in various sizes and coarseness levels, so choosing the right one for your specific needs can impact the final result.</p><h3 dir="ltr">Chemical Smoothing</h3><p dir="ltr">Chemical smoothing is a more advanced technique that can remove elephant foot and improve the overall finish of a print. In this process, a solvent is used to slightly dissolve the surface of the print, effectively smoothing out any imperfections. For example, acetone can be used for ABS prints, while a mixture of 91% isopropyl alcohol and salt can be used for PLA prints.[3]</p><p dir="ltr">Although it results in a smooth finish, chemical smoothing is not the most accurate technique for removing elephant foot. The solvent must be applied manually to the protruding areas with a rag; vapor smoothing will not work as this will also remove material from the intact areas.</p><h3 dir="ltr">Heat Treatment</h3><p dir="ltr">Heat treatment is another technique that can help in reducing elephant foot. By gently heating the affected area with a heat gun, the plastic becomes soft and can be carefully reshaped. This method is particularly effective for materials with a lower glass transition temperature, such as PLA. However, it requires a steady hand and careful control of the heat gun to avoid overheating and potentially warping the print.</p><p dir="ltr"><strong>Recommended reading: <a href="https://www.wevolver.com/article/3d-print-post-processing-steps-supports-sanding-smoothing-more" target="_blank"><em>3D print post-processing steps: supports, sanding, smoothing, more</em></a></strong></p><h1 dir="ltr">Conclusion</h1><p dir="ltr">3D printing, despite its many advantages, is not without its challenges, and the elephant foot phenomenon is one of them. This common defect can significantly affect the accuracy and aesthetics of a print. However, it is not an insurmountable problem. Through careful calibration and adjustment of slicer settings, it is possible to minimize and even eliminate the occurrence of elephant foot. Post-processing methods can also be employed to improve the quality of prints affected by this phenomenon. Understanding these strategies is crucial to achieving optimal results.</p><h1 dir="ltr">Frequently Asked Questions (FAQs)</h1><p dir="ltr"><strong>1. What causes elephant foot in 3D printing?</strong></p><p dir="ltr">The elephant foot effect in 3D printing typically results from excessive pressure exerted on the first few layers of a print. This pressure can be a result of incorrect bed leveling, excessive bed temperature, or a combination of factors.</p><p dir="ltr"><strong>2. How can I prevent elephant foot in 3D printing?</strong></p><p dir="ltr">Preventing 3D printing elephant foot primarily involves proper calibration of the printer, including bed leveling, z-axis calibration, and setting the correct bed temperature, as well as adjustment of slicer settings, particularly those pertaining to the first layer.</p><p dir="ltr"><strong>3. Can elephant foot be fixed after a print is complete?</strong></p><p dir="ltr">Yes, elephant foot can be addressed post-print through various post-processing techniques such as sanding, filing, chemical smoothing, or heat treatment. However, these methods should be performed carefully to avoid damaging the print.</p><p dir="ltr"><strong>4. How does the environment affect 3D printing and elephant foot?</strong></p><p dir="ltr">Environmental conditions, such as ambient temperature and humidity, can influence the behavior of the material during printing. An ambient temperature that&#39;s too high or too low can also affect the cooling rate of the printed layers, potentially causing elephant foot.</p><h1 dir="ltr">References</h1><p dir="ltr">[1] Skrzypczak NG, Tanikella NG, Pearce JM. Open source high-temperature RepRap for 3-D printing heat-sterilizable PPE and other applications. HardwareX. 2020 Oct 1;8:e00130.</p><p dir="ltr">[2] &Scaron;antak I, Duspara M, Cumin J, Kovačević B, Maglić L, Stoić A. Simulation of First Layer Adhesion Errors in 3D printing. TEAM2022. 2022 Sep 21:307.</p><p dir="ltr">[3] Gao H, Kaweesa DV, Moore J, Meisel NA. Investigating the impact of acetone vapor smoothing on the strength and elongation of printed ABS parts. Jom. 2017 Mar;69:580-5.</p>

Elephant foot is a common 3D printing issue

3D printing elephant foot is a common issue that most 3D printer users will have experienced. Typically caused by excessive heat or poor nozzle calibration, the issue can be solved in several ways.

Troubleshooting the 3D Printing Elephant Foot Phenomenon

<p id="isPasted">Mass manufacturing electronic textiles and in doing so combining textile fibers/garments as well as textile based wiring and sensors with PCB electronics is no easy task. A critical manufacturing challenge here has always been the creation of a reliable high-quality connection between textile wiring/sensors and PCBs/rigid components using a mass manufacturing machine. ZSK has innovated to solve this issue for embroidered electronic textiles. &nbsp;This article originally appeared <a href="https://www.techblick.com/post/embrioded-electronic-textiles-solving-the-textile-to-pcb-and-ecosystem-challenges" rel="noopener noreferrer" target="_blank">here.</a></p><p>ZSK will be exhibiting in Berlin at TechBlick&#39;s event on RESHAPING ELECTRONICS. &nbsp;Please join us and the entire global community on 17-18 OCT 2023. Lear more here <a data-hook="linkViewer" href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"><u>https://www.techblick.com/electronicsreshaped</u></a>&nbsp;</p><div data-hook="rcv-block3" type="paragraph"><br></div><p><a href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"></a></p><div data-hook="imageViewer" tabindex="0"><a href="https://www.techblick.com/electronicsreshaped" rel="noopener noreferrer" target="_blank"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTI2MjU3ODA0LTE2ODYxMjYyNTc4MDQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" alt="" data-pin-media="https://static.wixstatic.com/media/634751_9cf1c10eb91548198a7b527d61b55af7~mv2.jpg/v1/fill/w_1135,h_281,al_c,lg_1,q_80/634751_9cf1c10eb91548198a7b527d61b55af7~mv2.jpg" class="fr-fic fr-dii"></a></div><p><br></p><div data-hook="rcv-block6" type="image"><br></div><p><strong>Solving the textile-to-PCB connection issue</strong></p><p>As you can see in slide [1], typically PCBs do not lend themselves well to embroidery of electronics. This is because one often has loose connections, because the high thickness and the sharp edges act as failure points and because the large holes allow movement which loosens the connections. This means that it is not easy to achieve automatic manufacturing with standard PCBs in a reliable way.</p><p>This is why - as shown in slide [2] - ZSK developed the ZSK E-Tex-Board, which addresses the above mentioned issues, optimizing the board geometry (hole size, smooth edges, thickness, outer line design, etc) for mass embroidered e-textiles combining textiles wiring/sensors with PCBs.&nbsp;</p><p>As shown in slide [3], these special boards are also compatible with automatic placement machines, enabling a fully automatic manufacturing of e-textiles. This is an important step towards the realization of mass embroidered electronic textiles.&nbsp;</p><p>These PCBs - together with the ZSK&rsquo;s F-head for their embroidery machine - enable interesting opportunities. In the F-head, one can embroider the conductive threads with textile/garment to create wiring in the textiles. Using this head, one can also embroider insulating areas as needed, creating cross-overs which vastly improve wiring possibilities in tight spaces.&nbsp;</p><p>An example of a full system with embroidered conductive threads [wires] as well as crossovers and a stitched PCBs are shown in slide [3], showing how these innovations bring the entire system together, from conductive yarns to insulating to textile garments to PCBs and electronic components like LEDs etc</p><div data-hook="rcv-block18" type="paragraph"><br></div><p><strong>Solving the ecosystem issue</strong></p><p>ZSK has multiple other embroidery heads for different purposes [K-head for ECG and other sensors based on the moss embroidery and W-head for laying down tubes, fibers etc]. What is however of importance in our view is that they also offer business model innovation</p><p>They have correctly realized that the e-textile ecosystem is still immature and full of players each offering only a small part of the full system, which makes it very difficult for a potential end user to develop projects.&nbsp;</p><p>To this end, they have launched 3E Smart Solutions - an in-house engineering team - to help companies develop their ideas, prototype them, find manufacturing partners, etc. This fills an important void and we expect will accelerate the development of this industry &nbsp;</p><div data-hook="rcv-block28" type="empty-line"><br></div><div data-hook="galleryViewer"><div data-key="pro-gallery-inner-container" tabindex="-1"><div data-hook="item-link-wrapper" data-id="6cf29513-5f7f-4179-8b8a-06517f1e9ccb_0" data-idx="0" tabindex="-1"><div data-hash="6cf29513-5f7f-4179-8b8a-06517f1e9ccb_0" data-hook="item-container" data-id="6cf29513-5f7f-4179-8b8a-06517f1e9ccb_0" data-idx="0" tabindex="0"><div data-hook="item-wrapper"><div data-hook="image-item"><img data-fr-image-pasted="true" alt="" data-hook="gallery-item-image-img" data-idx="0" src="https://static.wixstatic.com/media/634751_4462c26945914d79aedc69a6a5d20bb1~mv2.png/v1/fill/w_960,h_540,fp_0.50_0.50,lg_1,q_90/634751_4462c26945914d79aedc69a6a5d20bb1~mv2.webp" data-pin-url="https://www.techblick.com/post/embrioded-electronic-textiles-solving-the-textile-to-pcb-and-ecosystem-challenges" class="fr-fic fr-dii"></div><div data-hook="item-hover-0"><br></div></div></div></div><div data-hook="item-link-wrapper" data-id="9ed71f4c-92f5-411a-a4b1-9884572c75e5_1" data-idx="1" tabindex="-1"><div data-hash="9ed71f4c-92f5-411a-a4b1-9884572c75e5_1" data-hook="item-container" data-id="9ed71f4c-92f5-411a-a4b1-9884572c75e5_1" data-idx="1" tabindex="-1"><div data-hook="item-wrapper"><div data-hook="image-item"><img data-fr-image-pasted="true" alt="" data-hook="gallery-item-image-img" data-idx="1" 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Mass manufacturing electronic textiles and in doing so combining textile based wiring and sensors with PCB electronics is no easy task. In this article, you will learn about an innovative approach to enable embriodery of PCBs and conductive wiring/sensors in mass produced e-textiles 

Embrioded Electronic Textiles: Solving the textile-to-PCB and ecosystem challenges

<p id="isPasted"><strong style="background-color: transparent;">3D printing</strong><span style="background-color: transparent;"> is a well-known Additive Manufacturing technique, it can create three-dimensional objects by depositing materials layer by layer. Processes such as SLA (stereolithography) and DLP (digital light processing) are in particular known for high precision and resolution. While it is compatible with various materials, including polymers, metals, and ceramics, and commonly used in rapid prototyping as it enables fast design iterations, it may not achieve the same level of precision as other techniques such as Electroforming and lacks the capacity for high volume production runs.&nbsp;</span></p><p><a href="https://insights.vecoprecision.com/electroforming-vs.-3d-printing-whats-the-difference" rel="noopener" target="_blank">-&gt; Learn more about the comparison of Electroforming and 3D Printing</a></p><p><strong>Laser Cutting</strong> uses focused laser beams to cut through materials, creating precise patterns and shapes. With Laser Cutting, intricate patterns with tight tolerances can be achieved. Although there are other advantages such as high precision and a wide range of compatible materials, it also has some limitations, such as HAZ (heat affected zones) which is thermal damage from the laser process.</p><p><a href="https://insights.vecoprecision.com/electroforming-vs.-laser-cutting-whats-the-difference" rel="noopener" target="_blank">-&gt; Learn more about the comparison of Electroforming and Laser Cutting</a></p><p><strong>Micro Milling</strong> is a Subtractive Manufacturing process that involves the removal of material using rotating cutting tools with very small diameters. This technique works with various materials, such as metals, ceramics, and polymers, and can achieve tight tolerances and smooth surface finishes. On the other hand, due to its vibration/rotating feature, an additional process for stabilization might be required when high precision cannot be compromised.</p><p><a href="https://insights.vecoprecision.com/large-volumes-small-parts-a-comparison-between-electroforming-and-micro-milling" rel="noopener" target="_blank">-&gt; Learn more about the comparison of Electroforming and Micro Milling</a></p><p><strong>Micro punching</strong> uses robust &lsquo;masters&rsquo; to punch holes in (mostly metal) substrates. As nozzle specifications have ever tighter tolerances, fewer masters can be used in parallel to reduce the variation. This slows down the production process while increasing the price.</p><p><a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank"><strong>Electroforming</strong></a><strong>&nbsp;</strong>is an additive manufacturing method that combines lithography with highly controlled electrodeposition which is highly suitable to create metal parts with micro holes of any shape. The lithography allows for small feature sizes with tight tolerances while electrodeposition grows a large number of parts in parallel without local damage or deformations. By combining several lithography and electrodeposition steps Electroforming can also integrate micro nozzles with channels, distance holders, or filtration structures.</p><p><span class="fr-img-caption fr-fic fr-dib" style="width: 768px;"><span class="fr-img-wrap"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTIzODU4Nzg5LVNjcmVlbnNob3QgMjAyMy0wNi0wNyBhdCAxNS40MS41OS5wbmciLCJlZGl0cyI6eyJyZXNpemUiOnsid2lkdGgiOjk1MCwiZml0IjoiY292ZXIifX19" style="width: 766px;" class="fr-fic fr-dib"><span class="fr-inner" spellcheck="false"><em id="isPasted">Examples of electroformed nozzles&nbsp;</em></span></span></span></p><p><span style="background-color: transparent;">When comparing 3D printing, Laser Cutting, Micro Milling, and Electroforming, many factors come into play. The choice of technology for producing micro-fabricated nozzle plates depends on the specific requirements of the application and the desired characteristics of the final product. Here we compare 4 key factors: Precision, Customization, Scalability, and Material capability.</span></p><p><strong>Precision:</strong> Electroforming offers the highest precision and accuracy, down to the sub-micron level, making it ideal for intricate structures and fine features. Laser cutting and Micro Milling offer good precision but may not achieve the same level of detail as Electroforming. 3D printing provides moderate precision, depending on the specific technology used (SLM, EBM, etc.).</p><p><strong>Customization:</strong> Electroforming allows for a high degree of customization, enabling the creation of complex geometries tailored to specific applications and the integration of additional functionalities such as channels into a single part. Laser cutting and Micro Milling also offer customization capabilities, but their potential may be limited by the complexity of the desired design. 3D printing provides the greatest design freedom, allowing for the creation of complex geometries and internal structures that may be challenging or impossible to achieve with other methods.</p><p><strong>Scalability:&nbsp;</strong>Electroforming is well-suited for large-scale production due to its high repeatability and consistency across multiple production runs. Laser cutting offers a moderate level of scalability, depending on the specific setup and materials used. Micro Milling and 3D printing are better suited for small-scale production or rapid prototyping, as their efficiency may decrease in larger-scale applications.</p><p><strong>Material Compatibility:&nbsp;</strong>Electroforming is focused explicitly on metal deposition, making it suitable for producing metal nozzle plates. Laser cutting and Micro Milling are also adaptable to a wide range of materials, such as metals, plastics, and ceramics. 3D printing can work with different materials depending on the specific technology, with metal 3D printing techniques like SLM and EBM being particularly relevant for nozzle plates.</p><p>In conclusion, Laser cutting, and Micro Milling provide normal precision and flexibility for applications not driven by extreme accuracy, while 3D printing offers unparalleled design freedom and material efficiency but is not comparable in precision. Electroforming excels in precision, customization, and scalability, making it particularly suitable for high-resolution and large-scale applications.</p><p><strong>Electroforming: Additive Manufacturing atom by atom</strong></p><p><a href="https://www.vecoprecision.com/electroforming/" rel="noopener" target="_blank">Electroforming</a> is an advanced Additive Manufacturing technology specialized for producing <a href="https://www.vecoprecision.com/products/" rel="noopener" target="_blank">high-precision metal parts</a>. Its uniqueness is that you can grow metal parts atom by atom, providing extreme accuracy and high aspect ratios. This process involves the use of an electric current to deposit layers of metal onto a substrate or mold, resulting in a highly accurate and precise reproduction of the original shape.</p><p>There are several key benefits that make Electroforming particularly well-suited for the production of <a href="https://www.vecoprecision.com/products/micro-nozzle-plates/" rel="noopener" target="_blank">micro-nozzle plates</a>. Micro-nozzle plates require a high degree of accuracy and precision to function properly, and the Electroforming process can achieve this level of precision with a high degree of consistency. In addition, the Electroforming process is able to produce complex shapes with a high level of detail, which is critical in the production of micro-nozzle plates. These plates typically include a large number of very small nozzles, which require a high degree of accuracy and precision in order to function properly. Finally, Electroforming is a highly efficient and cost-effective manufacturing process, which is important in producing micro-nozzle plates. These plates are typically used in high-volume applications, where the ability to produce large quantities of parts quickly and efficiently is critical.</p><p><span data-hs-drop="true"><a href="https://insights.vecoprecision.com/cs/c/?cta_guid=8681c2ee-0a4a-407d-9e8c-85b23a7efd3f&signature=AAH58kEMSQR3cdQZ8AGE7ZNxiT4RQ2CXcQ&pageId=112575129227&placement_guid=056f005b-1e5e-49f9-b6d2-99830614eb56&click=a5ddf881-0995-423e-accb-0f06b9110c8c&hsutk=97710d8cef260b164f288d3460335fe3&canon=https%3A%2F%2Finsights.vecoprecision.com%2Fthe-making-of-micro-precision-nozzle-plates-3d-printing-laser-cutting-micro-milling-and-electroforming-compared&portal_id=1788947&redirect_url=APefjpGd17WwmSDSm36cLF2XSoWjfQRHaa43B7la0_L-iM6yd-D3msMSyL_7WOcYhUunyYIO9Rnsyy6LZCiOKrgHSMm8dby6zx5aCkXoasfmrsiuGZ_KHd0HAKKcBiFDkw-30qOT32Hm9umHkcLDapHM6Z8qhrUHjo-Q6ZwFjNpCD86sdetQ8OV3iMLhYUCkyjf5p_sMHhOL_paAFhBBOh4FWI4QEgFpDxhInOyzVBM5W8zyCK_WZyamYi8Cb3kQp3UEpbm9qCgC_E0gLpsxb4dPtklv9wwWrXyHKsRtHYAk440OnPMAonY&__hstc=207439628.97710d8cef260b164f288d3460335fe3.1683536443459.1686041795655.1686123279027.13&__hssc=207439628.3.1686123279027&__hsfp=2288638424&contentType=blog-post" rel="noopener" target="_blank"><img alt="New Call-to-action" src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg2MTIzODIyNDI1LTE2ODYxMjM4MjI0MjUucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" class="fr-fic fr-dii"></a></span></p>

Micro-fabricated nozzle plates are used in various industries, such as inkjet printing, medical devices, and flow control. Manufacturing these nozzle plates requires precision and accuracy to achieve the desired performance. Several production technologies can be used to manufacture micro-fabricated metal nozzle plates, such as 3D printing, Laser Cutting, Micro Milling, Micro Punching, and Electroforming. 

In this article, we will introduce these production technologies, and illustrate how to find your preferred process for the production of micro-fabricated nozzle plates based on key features such as precision, customization, scalability, and material compatibility.

The making of micro-precision nozzle plates: 3D Printing, Laser Cutting, Micro Milling, Micro Punching, and Electroforming compared

Safety precautions like 3D printer enclosures can enhance the efficiency of air filters.

In this article, we look at the importance of using a 3D printer air filter to remove potentially harmful fumes from the print environment, as well as the different kinds of filter available and how to ensure proper maintenance.

Your Guide to Using and Maintaining 3D Printer Air Filters

According to manufacturer Creality, the Ender 3 print speed can reach an impressive 180 mm/s. But is it possible to successfully print at this high speed? If so, how?

Maximizing Your Ender 3 Print Speed: A Comprehensive Guide

<p id="isPasted">There comes a time in many product development cycles when parts hit a seemingly immovable wall known as design for manufacturing (DFM), or in the case of&nbsp;<a href="https://www.protolabs.com/en-gb/services/3d-printing/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0623&utm_content=wevolver-size-constraints-3dp-dt-0623" target="_blank">3D printing</a>, design for additive manufacturing (DFaM). At Protolabs, this wall is most often represented by a red icon which indicates a change is required, followed by some computer-generated text suggesting a possible course of action.</p><p>Such flags might include the ominous words &quot;Remove from Quote&quot; or a more agreeable &ldquo;Review and Accept.&rdquo; Whatever the case, it&rsquo;s important to recognise what the software is telling you and why it&rsquo;s saying it. You should also know that, even when the automated quoting tool seems to indicate that your design is doomed and you might as well go home for the day, alternatives exist. This design tip will describe three of the most common red flags in 3D printing, and offer a few helpful suggestions on ways to deal with them.</p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg1OTYxNTI5MjUwLVBpY3R1cmUxLnBuZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 488px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Oversized Parts</h3><p>The &ldquo;Part too big&rdquo; flag is perhaps the most alarming because it&#39;s followed by the to-the-point &quot;Remove from Quote&quot; command mentioned a moment ago. Surprisingly, this manufacturing constraint is one of the easiest to work around, but before going into the how, let&rsquo;s talk about the why.</p><p>As with any machine tool, 3D printers have set limits on bed sizes, thus defining the maximum size of workpieces a given machine can produce. Unlike most&nbsp;<a href="https://www.protolabs.com/en-gb/services/cnc-machining/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0623&utm_content=wevolver-size-constraints-3dp-dt-0623" target="_blank">CNC machining</a> centres, lathes, or EDM machines, though, 3D printers don&#39;t require that the part sits in a horizontal or vertical orientation during the manufacturing process.&nbsp;</p><p>Consider a spur gear like the one shown in Figure 1. There are many ways to process such a part, but on a CNC machining centre, it would most likely be clamped in a vice or fixture on the machine table, resting on the gear&rsquo;s flat backside. The same can be said for the&nbsp;<a href="https://www.protolabs.com/en-gb/services/injection-moulding/plastic-injection-moulding/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0623&utm_content=wevolver-size-constraints-3dp-dt-0623" target="_blank">plastic injection mould</a> used to produce this part, which would be milled or EDMed in the same orientation.</p><h3>Constraint Workarounds</h3><p>Let&rsquo;s pretend that the designer would like to 3D-print a prototype of the spur gear before investing in the fixture, vice jaws, or possibly injection-mould the part. She knows that the&nbsp;<a href="https://www.protolabs.com/en-gb/resources/design-tips/designing-for-stereolithography/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0623&utm_content=wevolver-size-constraints-3dp-dt-0623" target="_blank">stereolithography</a> (SLA) printers at Protolabs can produce parts up to 736mm x 635mm x 533mm in size (in normal resolution), easily large enough for the gear&rsquo;s 350mm maximum dimension.</p><p>But because she would like the gear to be very smooth and accurate, she chose to have it printed at micro-resolution using ABS-like MicroFine Green resin. However, this selection limits the maximum part size to 127mm across, leading to the &ldquo;Part too big&rdquo; warning and subsequent note that the part will be removed from the quote.</p><p>Undeterred, the designer decided to leverage 3D printing&rsquo;s ability to manufacture parts in any orientation, so she tipped the CAD model at an angle, sort of like squeezing an oversize birthday gift into a too-small box. She also selected high-resolution when submitting the quote, increasing the maximum part size to 254mm in each direction.</p><p>She quickly realised that tipping the gear means additional support structures are needed to constrain it during printing, thus increasing build time and part cost slightly. Sadly, she also found that the gear was still a bit too large by an inch or two, so she performed another additive-only magic trick&mdash;she sliced the part model into halves and modified it to include some mating pins and holes at the cut-line, intending to glue the pieces together after printing (a process that we call <em>cut and glue</em>). Problem solved.</p><p><br></p><p><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg1OTYxNTU2MTk3LVBpY3R1cmUyLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 416px;" class="fr-fic fr-dib"></p><h3 id="isPasted">Jumping the Gap</h3><p>Now take a look at the Small Gap warning in Figure 2. This indicates that the distance between each of the spur gear&rsquo;s teeth is less than the recommended 0.75mm, and that, depending on the 3D printing process, raw material, part geometry and orientation, the customer can expect partial or even complete fusing between some or all the teeth.</p><p>Here&rsquo;s one place where micro-resolution shines. As noted earlier, it supports features down to 0.07mm in the horizontal direction, one-half and one-fourth the size of high- and normal-resolution respectively. This statement also holds true for the Thin Wall warning seen in Figure 3. In this situation, the as-printed teeth might not meet the desired dimensional or geometric tolerances and could even break off during printing. Micro-resolution SLA and high-resolution <a href="https://www.protolabs.com/en-gb/services/3d-printing/direct-metal-laser-sintering/?utm_source=wevolver&utm_medium=referral&utm_campaign=uk-design-tip-0623&utm_content=wevolver-size-constraints-3dp-dt-0623" rel="noopener noreferrer" target="_blank">direct metal laser sintering</a> (DMLS) are the best option in each of these cases, size constraints notwithstanding.</p><p>&nbsp;<img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg1OTYxNTgwMDk0LVBpY3R1cmUzLmpwZyIsImVkaXRzIjp7InJlc2l6ZSI6eyJ3aWR0aCI6OTUwLCJmaXQiOiJjb3ZlciJ9fX0=" style="width: 407px;" class="fr-fic fr-dib"></p><h3>Grains of Salt</h3><p>Note the caveat from a moment ago, &ldquo;depending on the 3D printing process, raw material, part geometry and orientation.&rdquo; It&rsquo;s critical to remember that Protolabs offers five of the leading additive manufacturing (AM) technologies and over 25 different AM polymers, metals, and elastomers, each with its own unique properties and printability. This broad spectrum of manufacturing solutions means there&rsquo;s little we can&rsquo;t tackle, and that&rsquo;s not counting our other processes: CNC machining and plastic injection moulding.</p><p>But due to this complexity, a short design tip like this can only scratch the surface of what&rsquo;s possible or how to deal with any given design advisory. In our gear example, fixing a thin wall or small gap warning might be as simple as selecting a different polymer, or moving to a different 3D printing technology, or as we&#39;ve seen, changing print resolution. It could also mean skipping the 3D printer entirely and prototyping the part using our quick-turn injection moulding service, an option that&#39;s easier (and less expensive) than one might think.</p><p>The takeaway? Don&#39;t let red flags stop you. Use the automated quoting tool to get a quick price, narrow down your available options, and if you see something you don&#39;t like, don&#39;t understand, or can&#39;t figure out on your own, <a href="https://calendly.com/d/yyc-bqs-p9b?utm_source=protolabs&utm_medium=website&utm_campaign=uk-ae-meet&utm_content=3dp-design-tip-04-23" rel="noopener noreferrer" target="_blank">book a meeting with one of our application engineers</a>. And above all, don&#39;t be afraid to think outside the box.&nbsp;</p><p><br></p>

Navigating design for additive manufacturing advisories in your quote is easier than it seems, and it starts with thinking outside the box

How to Solve for Size Constraints, Small Gaps, and Thin Walls in 3D-Printed Parts

<p id="isPasted">Several post-processing options are available after printing a part via <a data-hook="linkViewer" href="https://www.makerverse.ai/technologies-sls" rel="noopener noreferrer" target="_blank"><u>Selective Laser Sintering (SLS)</u></a>.<a data-hook="linkViewer" href="https://www.makerverse.ai/polymer-3d-printing/the-guide-to-selective-laser-sintering-(sls)-post-processing#viewer-undefined" rel="noopener noreferrer" target="_self">&nbsp;</a>Some of these options are standard and applied to every part. Others are optional but can significantly impact the look, feel, and functionality.&nbsp;</p><p>So which <a data-hook="linkViewer" href="https://www.makerverse.ai/post-processing" rel="noopener noreferrer" target="_blank"><u>post-processing option</u></a> is suitable for your SLS components? This guide explains the different options and when to consider each one.</p><h2>Media Blasting&nbsp;</h2><div data-hook="imageViewer"><img src="https://images.wevolver.com/eyJidWNrZXQiOiJ3ZXZvbHZlci1wcm9qZWN0LWltYWdlcyIsImtleSI6ImZyb2FsYS8xNjg1Njk0OTkwNzAxLTQucG5nIiwiZWRpdHMiOnsicmVzaXplIjp7IndpZHRoIjo5NTAsImZpdCI6ImNvdmVyIn19fQ==" style="width: 766px;" class="fr-fic fr-dib"></div><p><span style="background-color: transparent;">This standard process is included in any order from the MakerVerse platform. Parts printed via SLS typically contain loose powder and a grainy finish, but media blasting remedies this. An abrasive media (such as sand or glass beads) is applied to the part under high pressure.</span></p><p>Media blasting&rsquo;s benefits are functional (gaining a specific surface roughness) and optical (a clean, polished surface). Once media blasting has finished, the production of the component might be complete &ndash; or the additional post-processing options detailed below might take place.&nbsp;</p><p><strong>When to use this</strong>: Always. Media blasting is a standard process that improves surface quality and removes excess powder.</p><p><span style='background-color: transparent; color: rgb(0, 0, 0); font-family: "PT Sans", serif; font-size: 26px; font-weight: 700;'>Media Tumbling</span></p><p>Media tumbling is a smoothing process that goes beyond what&rsquo;s possible with media blasting. During the tumbling process, the parts are added to a tumbler and then deburred, finely ground, and polished by the movements of the container. The result is a satin-like finish that is unattainable through media blasting.&nbsp;</p><p>However, the part loses some material during this process. This could impact the look and mechanical properties of the part. For example, if the part has sharp edges or fragile features, media tumbling can adversely affect the final result.&nbsp;</p><p><strong>When to use this</strong>: If a satin-like finish is needed and the part is not fragile.&nbsp;</p><h2>Vapor Smoothing</h2><p><span style="background-color: transparent;">This is another smoothing option. However, this one is performed chemically rather than mechanically. During vapor smoothing, the top layer of the part is dissolved in a vapor chamber. The result is a smooth and even surface that retains the part&rsquo;s mechanical properties.&nbsp;</span></p><p><strong>When to use this:</strong> When the surface needs to be smoothed and evened but is too fragile for media tumbling.&nbsp;</p><p><span style='font-family: "PT Sans", serif; font-size: 26px; font-weight: 700; background-color: transparent; color: rgb(0, 0, 0);'>Color Dyeing</span></p><div data-hook="imageViewer"><img src="https://s3-us-west-1.amazonaws.com/wevolver-project-images/froala%2F1685695159235-3.png" style="width: 766px;" class="fr-fic fr-dib"></div><p><span style="background-color: transparent;">Parts printed through SLS are typically white, so adding additional colors is a popular in post processing. The SLS component is immersed in a water bath with a colored dye of choice in the dyeing process. The resulting chemical reaction causes the dye to penetrate the component, adding a homogenous color gradient to the part.&nbsp;</span></p><p><strong style="background-color: transparent;">When to use this:&nbsp;</strong><span style="background-color: transparent;">&nbsp;When only a single color is needed or if the part has a complex geometry&nbsp;</span></p><p><span style='background-color: transparent; font-family: "PT Sans", serif; font-size: 26px; font-weight: 700; color: rgb(0, 0, 0);'>Painting&nbsp;</span></p><p>In painting, a professional spray painting systems adds additional colors to the printed part. The part is cleaned and a clearcoat is applied to protect the paint. With painting, there&rsquo;s a nearly infinite range of colors, but it can be difficult if the gemoetry of the part is complex.</p><p><strong>When to use this</strong>: When multiple colors or a range of colors are needed. Ideal for evaluating a printed prototype.&nbsp;</p><h2>Quality Measurements</h2><p>Quality measurements don&rsquo;t change the properties of a part, but this can be an invaluable process that ensures that the part is printed exactly as expected. There are <a data-hook="linkViewer" href="https://www.makerverse.ai/quality-offering" rel="noopener noreferrer" target="_blank"><u>several quality measurements</u></a> available on the MakerVerse platform.&nbsp;</p><p>Optical 3D Scan: High-quality stereo cameras compare the original design geometry with the finished part. With the false-color image provided by the scan, it&rsquo;s possible to spot geometric deviations from the original design. This option is ideal for a quick evaluation of dimensional stability<a data-hook="linkViewer" href="https://www.makerverse.ai/polymer-3d-printing/the-guide-to-selective-laser-sintering-(sls)-post-processing#viewer-undefined" rel="noopener noreferrer" target="_self">.</a></p><p>Surface Roughness: A sensitive stylus measures the roughness of a part&rsquo;s surface. Best performed when the statistical deviations of a surface from the ideal form are required.</p><p><strong style="background-color: transparent;">When to use this</strong><span style="background-color: transparent;">: Whenever in-depth quality control is needed. It can be helpful before sourcing a larger batch of parts.</span></p><p><span style='font-family: "PT Sans", serif; font-size: 26px; font-weight: 700; background-color: transparent; color: rgb(0, 0, 0);'>Next Steps</span></p><p><span style="background-color: transparent;">When creating parts using SLS technology, choosing the suitable post-processing options is a critical step. Selecting the right choice can affect the appearance and functionality of the component, so be sure to give proper attention to post processing.</span></p>

3d printing