Why am I getting this Z drag on the top layer of my prints on A1 Mini?

I cannot figure this one out and kindly need help. I am trying to make a simple outline of a cat with a flat top layer. But the top layers are always getting, what I am assuming, are Z drags.

I have been adjusting the Z retraction. No luck at .05, 1, and finally 3mm. I tried top layer Concentric, Rectangular, Monotonic and Monotonic Line options. Adjustments are made on the filament settings.

What am I doing wrong? (FYI the sides have a fuzzy design, which is why the edge looks rough)

Ironing makes it better, but it pushes too much material to the edge.

I made sure the print head secured, and screws around it tight. Recalibrated the printer twice. Fresh PLA from overture.

In the photo below the left one is about 6" tall and right one is 3". Both are .20" tall.

Started with .20 Standard settings.

Thanks again for any help!

Welcome to the forum.

The different directions of the top layer make me think that the model isn’t flat on the bed.

Are you able to upload the .3mf file or show a picture of the sliced top layer?

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Yeah it’s odd they both have the same pattern on them. I was also going to suggest not using grid infill as it likes to grind too.

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@JonRaymond
Ahh… you may be onto something. I double the height to .40" and gave it a fresh slice down the middle of the z plane & deleted the top. Sliced the bottom and it looks different. Test printing it now on regular .20 standard.

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@johnfcooley Have not played around much with the infill options. Thoughts on an infill for this type of print and why? Thanks!

Gyroid dosen’t cross itself, cubic I use alot.
May want to increase top layers as well so you don’t see the outline of infill when it’s done. I really only use those two most of the time with crosshatch as well.

You can play with them by making a 2-3mm square with no top layers, varying the infill on each. There are also prints you can download on Makersworld to see what they are.

Missed the “and why”. I use mostly becasue I don’t get that scrape, as well as some are better for strength. Some infills combined with wall strength and line width can create some very strong prints with PLA.

If you’re doing mainly prints like the one shown then it won’t really matter that much. Strength isn’t the goal but finish. Top layers will hide the little droop that happends when it bridges over putting down the top layers. Especially if you use a less dense infill pattern.

Awesome and thank you!
Test print came out better and will try more of these.

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So my 6" test print had the same issue in the real life photo above. But this time on the slicer preview it shows 2 of the many lines. Pic below.

I am wondering if my plate is too hot and warping the plastic during printing, causing it to bow. Basically what @JonRaymond suggested earlier. Downloading test print files from Makerworld to try things.

Your issue isn’t a bed adhesion problem. The model isn’t sitting flat in the slicer or there is an issue with the part stl.

Are you able to upload the .3mf file here?

@JonRaymond sure thing and thank you.
Cat Export 3MF.3mf (523.0 KB)

As expected, the original file has a step in it because the model isn’t parallel top to bottom.

To fix it, I sliced the top off so it’s parallel to the bed.

And then scaled it in Z back to your original dimension.

Now the top slices uniformly.

Attached is the fixed file.

Cat - Fixed.3mf (173.5 KB)

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@JonRaymond
First, a big thank you for this effort.
Second, how did you find the “step”? Manually looking for it or some other way?

Appreciate it!

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You can find the “step” by using the preview pane of the slicer, and inspect the rendered model on your monitor.
It is especially visible in this case, as the final layer is the undesirable “top step.” So if you move up and down the layers via the right-side layer navigator, the top being a noncomplete outline of the model should ring alarm bells right away

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Got it. But there is no “feature” to find steps on what should be a 100% flat plane?

what should be a 100% flat plane

The model is occupying it’s defined space, it just happens to have a slightly skewed 90.5 degree angle as its top surface.

It only becomes a “Step” when you slice it and the program has to decide if plastic goes there or not. At some point, that angle started making the model occupy more than 50% of that 0.2mm layer height, and the slicer made a decision to fill it with plastic.

In whatever modeling software was used to make this, I would suspect you can measure angles. The slicer doesn’t know you want that surface to be a flat plane with respect to Z. If you want it to be a flat plane, and it isn’t a flat plane, you do what JonRaymond did, and perform a planar cut.

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Bravo!

So as a follow up, I did the print this using the new file sent to me by @JonRaymond . It is much better, but the lines are still there.

Pics & settings below. I made this one 5" tall instead of 6" to speed up print time. Same thickness at.20". Fuzzy settings off. I also did a 50% sparse infill density. It is almost like the fill pattern can only be “so big”.

zdrag4
zdrag5

Last night I downloaded and printed this on normal .20 standard. It came out looking great. Granted the height of the white cubes are .04". Top Surface Patterns Display Test by Luca2210 - MakerWorld

If you follow the Gcode preview it shows why those lines are there as the top layer isn’t continuous. This is normal slicing behaviour
Cat top layer

You can minimalize these lines by

  • Calibrating your filament (as you are slightly over extruding)
  • Using a non-crossing infill like gyroid
  • Ironing the top surface
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Here is an update after a manual filament calibration. Fuzzy walls, 25% gyroid fill, monotonic top layer & 5 top shell layers. No z retraction. Left is not ironed & right is ironed.

This is drastically better. The previous results were deep physical marks (assuming not actually a z drag issue at this point). The surface of both is consistent and the marks you do see cannot be felt. Ideally I would love to remove these noticeable marks as to only see the monotonic pattern. I am assuming we may be at a physical limitation of the machine, or more likely, my knowledge.

Any thoughts moving forward? As simple as these are, this has been a great learning experience for me.

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I think you’re looking great here.

You may be able to tune your ironed edge’s pits a little better by using more than 1 wall on the top surface. Bambulab software by default enables 1 wall on top, which helps look good without ironing. but… Ironing avoids the edge at about the same width as half a wall. If you have more walls for it to smooth over, those spots where pits can form (gap between top solid surface + wall) are moved inwards in the model, and thus get a couple passes from the iron.

You may end up trading the pits on the inside edge of your outer wall for overflow/flashing on the outer edge of your outer wall, but idk, if you want to test, try it out.

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