Failed 3D print of vertical rounded edges

I have a problem printing vertical rounded edges. The model has a 30deg angle and then a fillet to the vertical edge. When i print half of it, it looks ok, but when i print the whole model (which is actually part of a larger model) the fillet prints bad. (see image).

I tried various inner outer wall and also speed changes on overhangs (see 3mf) but they all fail. What’s the trick to get this to print properly?

test-object.3mf (66.8 KB)

A 30 deg overhang (what you have here) is at the limit of printability without using supports. If you are using PETG it is even worse. With the little information provided there are several things to check/try.

  1. First make sure your filament is dry. Right out of the package is not dry.
  2. Once your filament is dry, perform a full filament calibration. K-factor, flow ratio, speed, temperature, overhang
  3. You may need to use supports which can take some tuning as well.

I understand and appreciate cutting the part into test pieces. By doing so, you are changing the thermal properties of the part during the print. The orientation of the part to the cooling fans can have a huge affect when printing parts like this.

Don’t look at this as a roadblock, see it as an opportunity to learn and become proficient.

thanks, i appreciate the response. not sure what K-factor is but most others i have checked. I dried the filament for 6h in my AMS2, maybe not the best dryer but should be good, also because the object half is looking good to me. I intentionally started the face with 30deg as that usually works good on my printer for overhangs. and the rest of the fillet is angling steeper so should not need supports. i will draw supports on there to see what happens and will post here.

Adding supports did not make a difference. the object is still looking quite bad. But I reduced the overhang speeds even further than the default and with these settings, it printed almost perfectly:

I don’t understand completely why it printed so bad with the default but this works for me.