3D Printing Misalignment of layers Problems – solved
Misalignment of layers – Most 3D printers use an open-loop control system, which is an elegant way of saying that they have no feedback on the actual location of the extruder. The printer tries to move the extruder to a specific location and waits for it to get there.
In most cases, this works well because the stepper motors that move the printer are actually stronger, and there are no significant loads to prevent the extruder from moving. However, if something goes wrong, the printer cannot detect it. For example, if you collide with the printer while it was printing, you can cause the extruder to move to a new position. The machine has no feedback to detect this, so it would continue to print as if nothing had happened.
If you notice a misalignment of layers in your printing, this is usually due to one of the causes below.
The extruder moves very fast
Printing at a very high speed can prevent the 3D printer’s engines from following the print. when you try the printer to move quickly more the the engines can move, you will commonly hear a click when the engine cannot reach the desired position. When this happens, the rest of the print will be misaligned with everything that was printed before it.
If you think your printer may be moving too fast, try reducing your printing speed by 50% to see if it helps. The standard print speed controls the speed of any movements in which the extruder is actively extruding plastic. The speed of movement of the X / Y axis controls the speed of rapid movements in which no plastic is being extruded. Try to adjust both to try to solve the problem.
If any of these speeds are too high, it can cause changes. If you want to adjust more advanced settings, also consider lowering the acceleration settings in your printer’s firmware to provide more gradual speed and increase.
Mechanical or electrical problems
If layer misalignment continues, even after reducing the print speed, this is likely to be due to mechanical or electrical problems arise to the printer. For instance, usually every 3D printers make use belts that enable motors to control the position of the extruder. The straps are typically made of a rubber material and reinforced with some fibre to provide additional strength. Over time, these belts can stretch, which can affect the tension of the belt used to position the tool extruder. If the pressure becomes too loose, the belt may slide over the top of the drive pulley, which means that the pulley rotates, but the belt does not move with it.
If the belt was initially installed extremely tight, this could also cause problems. A belt that is too tight can create excessive friction in the bearings, preventing rotation of the motors. Optimal assembly requires a belt that is a little tight to prevent slipping, but not too tight where the system cannot rotate.
when you start to observe problems with misaligned layers, make sure you check that all of your belts are properly tensioned and that none of them appears to be very baggy or very tight. but when you realise there may be a problem, consult the printer manufacturer company for guidance on how to adjust the belt tension.
Most 3D printers also comprise a range of belts driven by pulleys connected to a stepper motor shaft using a small fixing screw. These fixing screws anchor the pulley to the motor shaft so that the two items rotate together. However, if the screw loosens, the pulley will no longer rotate together with motor shaft. This tells that the motor may signify spinning, but the pulley and belts do not move. When this happens, the extruder does not reach the desired location, which can affect the alignment of all future printing layers. Therefore, if the misalignment of the layer is a recurring problem, check that all engine screws are properly tightened.
There are also several other common electrical problems that can cause engines to lose position. For example, if the motors don’t get enough electrical current, they won’t have enough energy to spin. It is also possible for the driver’s electronic components to overheat, which causes the motors to temporarily stop turning until the electronic components cool down.