Issue with overhang to outer wall transition

Helly everyone,

I have an issue which is I guess the transition from small overhangs to solid walls. If you take a look at the pictures I have a tabletop terrain miniature model with brick walls and some other structures and every time there is a small overhang there is a fine line that is continued after the printer switches to the solid wall.

I use BBL PLA Though with H2D and 0,4 nozzle.

And I have:

  • done all calibrations etc. even the one with the vision encoder,
  • changed speeds,
  • lowered line height,
  • changed fan speeds and printed something so the direction of the air is different,
  • lowered and increased the smooth coefficient,
  • printed with infill 100% instead of the usual 5-15 %,
  • increased walls,
  • increased and lowered wall thickness,
  • changed seam position etc.,
  • and much more…

I think the problem is the transition from overhangs to outer wall:

But I am pretty clueless what I can do more now… maybe someone has an idea.

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Did you tune PA? Looks like a pressure advance issue. Slowing down the outer wall speed to something like 60mm/s should help with overhang performance by giving the fan more time to cool the extrusion. You can try 3 walls and inner/outer/inner wall order. Also reducing the layer height will help with overhangs.

I did both flow calibrations to tune PA and latest tries were 3 walls with starting 50 down to 10 mm/s. Layer height was 0,16 mm and I tried all wall order combinations as well. Best result with the lines still but less visible was outer/inner, but it was bad for the overhangs.

that happens because it needs to slow down for the overhang, then the cooling time on that layer is higher than on the remaining, you can either slow down everything , or uncheck the slow down for overhangs - which will deteriorate a bit the quality, but given they are so small it might be ok

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Slowing down everything to 10 mm/s + inner/outer/inner walls created too thick layers… 25 mm/s to thin. Now with 15 mm/s it is mostly fine… but damn, this means the print will take forever.

yep that’s the compromise if you want the best surface possible, or you can speed it up a bit and live with a bit of a mark, it really depends on how you want the end result to look like without post-processing

edit/ you can also consider doing two walls only and printer inner/outer, that might give you 25mm/s with a good thickness (using arachnae)

Or carbon fill. Bambu just had a really good sale on cf-PLA. CF or GF hides pretty much everything. I really like cf-PETG and ABS-gf for prints that I need to look not 3d printed

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