What Is Warping, and Why Does It Happen in 3D Prints?
Warping is one of the most common mistakes in 3D printing. It occurs when the plastic filament cools and shrinks at different rates, causing the printed object to deform. It often happens at the edges of the print, where the filament is cooling fastest.
To prevent warping, it is important to use a heated build plate and to enclose the printer in a space where the temperature is controlled. Additionally, some filaments are less prone to warping than others. For example, PETG and ABS have a higher glass transition temperature than PLA, meaning they are less likely to warp when cooled rapidly. By understanding the causes of warping and taking steps to prevent it, you can ensure that your 3D prints come out looking their best.
4 Main Causes of Warping
Why do prints warp? Let’s examine some of the most frequent causes.
1. Temperature Differential
This is one of the primary causes of warping. When the temperature of the build chamber varies too much, it can cause uneven cooling and contraction, leading to warping. For example, if the print cools too quickly, it can warp before it has had a chance to solidify properly. This can be due to poor ventilation, insufficient fan speed, or using the wrong type of build material.
Conversely, if the build plate is too hot, the plastic will soften and sag, also causing warping.
2. Improper Bed Adhesion
If the 3D print doesn’t stick well to the build plate, it can easily warp as it cools and contracts. This can be caused by several factors, including incorrect bed leveling, use of the wrong type of adhesive, incorrect nozzle height, insufficient extrusion, or not cleaning the bed properly before printing.
3. Incorrect Slicing Settings
The slicer software determines the ideal path that the 3D printer should take to create the desired object. This path is calculated based on many factors, including the orientation of the object, the type of material being used, and the desired resolution. If any of these settings are incorrect, it can cause the object to warp during printing. In addition, incorrect slicing settings can also cause sections of the object to detach from the build plate during printing. These detachments can also lead to warping and inaccuracies in the final object. As a result, it is essential to ensure that all slicing settings are correct before beginning a print job.
4. Printing Too Fast
Printing too fast can cause warping for a few reasons. First, when the extruder moves too quickly, the plastic filament can start to curl up instead of lying flat. This causes the prints to warp and can result in poor print quality. Second, if the build plate is not heated properly, the warmer bottom layer can cause the top layers to warp as they cool. Also, printing too fast can simply cause the plastic to cool too quickly, which makes it more brittle and prone to warping.
6 Ways to Prevent Warping in Your Prints
Several things can be done to minimize the risk of warping. These include:
1. Designing Objects With a Large Surface-Area-to-Volume Ratio
One of the most important considerations when making 3D printables (see our guide to making 3D printables in Blender) is to ensure that they retain their shape even after printing. This is particularly important for objects that are subject to stress or heat, as warping can cause serious problems. One way to prevent warping is to design objects with a large surface-area-to-volume ratio. This means that the 3D object has a large amount of surface area relative to its volume. This is often accomplished by making the object thinner or by increasing its surface area.
Objects with a large surface-area-to-volume ratio are less likely to warp because the forces acting on them are distributed over a larger area. As a result, they can maintain their shape even under significant stress or heat. This principle is used in various engineering applications and can be an effective way to prevent warping.
2. Using Supports During the Printing Process
One way to help prevent warping is to use supports. Supports are attachment points that hold the build in place as it cools, preventing it from warping out of shape. In addition, by using supports, manufacturers can create parts with more complex shapes and geometries. As a result, supports are an essential tool for achieving success with 3D printing.
3. Controlling the Cooling Process
The risk of warping can be reduced by controlling the cooling process. One way to do this is to use a cooling chamber, which helps to regulate the temperature and prevent uneven cooling. Another option is to use materials that have different melting points so that they solidify at different rates. By controlling the cooling process, it is possible to prevent warping and produce high-quality 3D prints.
4. Using a Heated Build Plate
Keeping the build plate warm helps to prevent the filament from cooling too quickly and contracting. In addition, a heated build plate can help to improve adhesion. This is especially important when printing with ABS plastic, which is known for being difficult to adhere to the build plate. As a result, using a heated build plate can be an effective way to prevent warping and improve the quality of your 3D prints.
5. Using a Brim or Raft
This is essentially an extra layer that you add to your print that helps to keep it attached to the build plate.
These are both layers that are printed around the perimeter of your object. They help to keep the object from warping by providing a larger surface area for adhesion. The brim is a single layer that is typically removed once the print is complete. A raft is a multi-layer structure that remains attached to the object. It can be more difficult to remove, but it provides a greater level of support.
6. Try Changing Your Printer Settings
Change the printer settings such that the outer perimeter of your print is printed at a higher temperature than the rest of the print. This will help to create a stronger bond between the outer perimeter and the build plate, which will in turn help to prevent warping.
You can try increasing the temperature, slowing down the cooling, or even using a fan. These settings will vary depending on the type of filament you’re using, so it is important to do some research before you start printing. With a little trial and error, you should be able to find the perfect settings for your printer and filament combination. Warping will no longer be an issue, and you’ll be able to produce high-quality prints.
Understand What Causes Warping to Know How to Avoid It
To prevent warping, it is important to understand the root cause of the issue. There are several ways that you can combat warping in 3D printing as we have discussed in this article. Ultimately, it is up to you as the 3D printer operator to determine which methods work best for your specific needs.
