What is causing this defect?

I am trying to print this small component in ABS. It’s size is roughly 60mm x 40mm.

No matter what I do the print has horrible defects on the radiuses corners that make the result look ugly:

from a different angle ie the print bed side:

Obviously these are unsupported corners, so I have tried all types of supports, auto and manual. The results above are the best I could get, and still not what I would like. I achieved these results with these manual supports:
Screenshot 2024-03-19 at 10.23.07

Note I have tried three different spools of BBL ABS and ASA, but the defects are the same. One of my tricks in the past is to use a raft, but that ends in disaster, especially when I used a very fine layer height.

I tried slowing all the speed and acceleration parameters down to a ridiculous extent but again the result is still horrible.

I do my designs in Onshape, so if you want to have a go a printing the part, here is the link : Onshape

What can be done to reduce the issue? It is possible for me to change the design within reason, but don’t really want to. I would prefer to change the printer parameters for a better result.

Thanks for your help

Fillets that start on the bed always look bad, at least me too. Try using a chamfer at the bottom then add a fillet to top edge of the chamfer so that it has one square corner that you could wet sand round after printing. Like this
image

3 Likes

Hi Duane,

That’s a very sneaky idea you gave me. Many thanks…

One other idea I have; and I’ve never tried this, so shoot me down if you think it’s stupid, is to make some ABS paint, by diluting ABS waste in acetone. I think I would need to experiment quite a bit though…

Cheers

Wellco

Organic support may be easier to remove for this geometry.

Thanks @CanDo.

I did try all the different support types and yes tree supports were slightly easier to remove the result was still ugly…

Hello, I am also fairly new to printing with ABS and have had good results. I have downloaded a copy of your component and have made some small alterations. I will test print this tonight on my P1S and provide you some valuable feedback soon(hopefully).

Wow, I will be very interested to hear your results. Thanks for having a go… Much appreciated

Wellco

Hello I cannot seem to upload or attach images to this forum. What am I missing please?

Hello wellco. I have essentially reduced your edge fillets by half and changed the print position. I have also removed your screw holes for simplicity. I had good results printing with Bambu ABS.

I can’t figure out how to attach images to this forum post. Perhaps someone can assist me?

@Stedyone01 Just drag and drop the image and wait for it to upload. At least that’s what I do using Safari on a Mac.

would be good to see your results if you can manage it.

Thanks for trying

Wellco

Or just paste (Ctrl-V) the image inline with the text (Windows)

I’m afraid the forum is still not allowing me to add any images. I keep getting “An error occurred: Sorry, you can’t embed media items in a post.” I wonder if it’s because I’m so new to the forum?

Yes that is the reason. I had a similar issue just being able to create my post.

You have to go through about 20 stupid steps before they deem you to be a qualified contributor.

Seems quite childish if not patronising to me.

I guess its a one-time thing though…

Sorry!

Its not childish or patronizing.

Its to keep the bots and spammers down to a very minimum.

And it works also.

1 Like

I’m having the same issue (using PLA), it’s driving me crazy.
The thing that gets me is that I printed a side spool holder:

and when I see other people pics the bottom end/overhang came out super nice but no one has put if they used different settings. I slowed it down, changed filament, used adaptive and used supports. What are we missing here with this issue if for other people it comes out fine?

There I have completed my user profile. let’s see if I can finally attach images now.



I realise what it’s doing and why it is needed, but it doesn’t have to be done in a childish and patronising way. AGAIN “as it seems to me”. You may not think this, but I do.

Thank you

I think it’s the larger fillet there coming up right from the first layer on the bed. Can you place the side where your hand is on the bed to print? Bed placement is a key component to a successful print!

Hey @Stedyone01 That looks really great! I might give that a go, but I do need the screw holes in some form so that I can fix it to my bike…

I will say it again. It’s not childish or patronizing. Its industry standard.

1 Like