3D Print Pillowing: Causes and Solutions
Even after setting up your printer and printing multiple times, you still can't get a good top layer. This is an issue that many users of 3D printers have faced. Pillowing, which causes your prints to have a bumpy top, may be really annoying when printing is going well until the very end. In order to help users, we have created a basic "how-to guide" on fixing top layer issues (pillowing) with some options that you can test out immediately.
How Does 3D Printing Affect Pillowing?
The term "pillowing" describes a problem that might arise in 3D printing when the top layers of the object are not smooth and flawless. Another probable explanation is that a lot of time and materials are wasted on a print that doesn't turn out properly due to pillowing, which is frustrating because it isn't visible until the print is finished, unlike other 3D printing problems.
If the parameters are wrong, pillowing might still cause trouble even with a top-tier 3D printer. Spaces and holes that resemble pillows happen when the upper layers of a 3D-printed object don't have enough time to cool or there aren't enough materials on top. Fixing it should be possible with the aid of the solutions given below.
When Does Pillowing Happen? What Causes it?
There are a lot of potential causes for these 3D print flaws, including holes and gaps. It is more probable for pillowing to happen when there is insufficient layer cooling or when the top layer is too thin.
i) Inadequate Cooling
This is due to the filament's contraction as it cools and travels from the infill to the nozzle. The reason behind this is that when the material compresses, it sticks to the infill but warps to the spaces below. The inadequacy of the power of your layer cooling fans to adequately heat the material could also be a contributing factor. If you print too quickly, the materials won't have time to cool down properly, and you'll still get the same result.
ii) Insufficient Supporting Material
When a print job is complete, just click the button up top to close it. In addition, prints without sufficient strong top layers are more prone to pillowing. The primary reasons behind this pillowing problem are inadequate cooling and improper print settings.
iv) Improper Filaments
Additionally, remember that this is more likely to occur with 1.75mm filaments (the industry standard) rather than 2.85mm filaments. Although there are certain ways to prevent pillowing, it tends to occur more frequently with filaments that are either too soft, like TPU, or too hot, like ABS and polycarbonate.
How to Prevent Pillowing in 3D Prints?
1. Increase Top/Bottom Thickness
If the top thickness is too thin, it will result in a surface with holes in it. That being said, raising the Top/Bottom thickness in the slicer will help seal the top surface of your print better. If your model's top surface is flat, you should close it with a Top/Bottom thickness that's six times the layer height.
A top and bottom thickness of 0.6 mm is necessary, for example, if the layer height is 0.1 mm. If the print's top surface isn't waterproof currently, increasing the Top/Bottom thickness might fix it. The basic rule is that as layer height gets thinner, the number of top layers needed increases. Thinner layers need more material to close the top completely since they curl or break more easily.
2. Use a Fan to Reduce the Temperature
If your layers don't cool down sufficiently, pillowing could still happen regardless of how properly you configure things. Use a slow-speed fan for the initial layers; increase the speed after that. If a cooling fan is already in your arsenal, ensure that it is directed towards the print for the best air circulation. When cooling is inadequate, the material curls up at the intersections of the infill lines, resulting in holes in the top layer. Make sure the fans are running at full speed by following the cooling settings precisely.
The first fan in your 3D printer, the layer cooling fan, is meant to swiftly lower the temperature of the filament layers after deposition; it's situated near the nozzle. The structural stability of the printed layers depends on their proper solidification. The second fan is the hotend fan, and it's vital for maintaining the correct temperature at the top of the hotend and preventing the filament from being mistakenly softened as heat rises. However, it might be helpful if you avoid starting the print under extruding before reducing the printing temperature. The situation may become even more dire if it becomes necessary to completely disable the print speed.
Purchase Link: Amazon
Price: $8
3. Maintain the Recommended Infill Density and Pattern
You need to adjust the infill settings so that more materials cover the top levels, making them stronger and adding more internal support structures. It is crucial to optimize your 3D printing setup by finding the optimal print time and material. By evenly spreading support over the inner structure, infilling patterns like honeycomb and gyroid provide stability without increasing rigidity. To modify the spacing and thickness of the fill, navigate to the Infill tab.
While you may always add more infill if necessary, a range of 15-50% is usually sufficient for most standard prints. Somewhere between fifty percent and one hundred percent is the sweet spot for realistic 3D prints.
4. Slow Down the 3D Printing Process
To prevent pillowing, reduce the printing speed and wait for each layer to cool completely before adding another. The material can maintain its softness if the speed is high enough to permit the deposition of successive layers before they cool down enough.
Start by reducing it from the default value if you wish to find the sweet spot. You should consider both the average and maximum speeds when you optimize your 3D printer. The maximum speed dictates the degree of 3D printing in the upper layers. Be cautious not to drastically reduce the speed when you alter it to prevent under-extruding.
5. Adjust 3D Printing Settings for Pillowing Filaments
Pillowing and distortion are possible problems with some filaments, especially supple and flexible ones, due to the fact that they retain heat for longer durations. As a result, surfaces may have unintended consequences due to insufficient cooling between layers. Their flexibility and pliability render them prone to deformation when cooled, and their rigidity hinders their ability to sustain the layers above them, jeopardizing structural integrity.
To avoid this issue and achieve better print quality and layer adhesion with these materials, adjust the cooling settings, print speed, and temperature appropriately. To avoid weakening the structural integrity of the layers, it is important to use a high-quality filament (maybe the best filament for 3D printing) that is constant in diameter across the board, free of contaminants, and flexible yet soft.
Having looked at pillowing in 3D printing and how you can prevent it, it’s also important to have a look at best 3D printing software that you can use to prepare your files. There are many that are available, but we recommend using SelfCAD. It is one one of the easiest 3D design software available that you can use to create 3D models from scratch using the various tools like the freehand drawing and sketching, image to 3D model, sculpting tools, as well as various modification and deformation tools. The video below shows the overview of SelfCAD.
You can also import files designed in other programs and modify them in SelfCAD with ease. In addition to 3D modeling tools, SelfCAD also comes with an in-built online slicer that you use to slice your files and generate the G-code to send to your 3D printer.
Achieving Perfect Top Layers
Ultimately, tackling 3D pillowing calls for a mix of tactics designed for different printing situations. Through the exploration of these cutting-edge methods, users can conquer the obstacles of pillowing and accomplish prints of exceptional quality with enhanced surface finishes. With the rapid advancement of 3D printing technology, consumers have access to an ever-growing arsenal of options. This creates a constantly changing landscape that is exciting for both hobbyists and professionals.
Enjoy powerful modeling, rendering, and 3D printing software tools without the steep learning curve.
Need to learn 3D modeling? Get started with interactive tutorials.