Print Process Case Studies

Click a thumbnail image below or select the “Download PDF” button, to view the full case study.

Case Study:
Gonzaga University Transforms Ankle Foot Orthosis (AFO)

Problem:
Drawn out design process, high costs, extensive production time

Solution:
High Quality Rapid Prototyping 3D Printing

Case Study:
U.S. Architectural Lighting saves $50,000 Annually by 3D Printing Casting Masters

Problem:
Expensive service bureaus and lengthy product delivery

Solution:
Implement internal 3D printer to save time and money

Case Study:
Oozing Filament & Poor Print Quality

Problem:
Bulging, oozing, oversized beads of filament

Solution:
Reduce the nozzle temperature and decrease flow rate

Case Study:
Thin Walls & Damaging Supports

Problem:
Thin walls, steep overhangs and weak parts

Solution:
Increased fill percentage and double support structures

Case Study:
Common Model Errors

Problem:
Models can exist in the virtual world, but not the physical world

Solution:
Utilize software with file repair features, you can create one solid file that does not have intersecting surfaces

Case Study:
Blobs and Zits

Problem:
Retraction settings and distance are not setup correctly, as well as bad start points

Solution:
elect a proper retraction distance and a start point closest to specific location

Case Study:
De-Laminating Layers

Problem:
Poor quality material, print temperature too low

Solution:
Changing to a higher quality material/supplier, raising the active print temperature

Case Study:
Separation LayersSeparation Layers

Problem:
Separation layers not set correctly, printing directly in contact with solid layers

Solution:
Adjust separation layers and distances allow for easy removal of support material

Case Study:
Stringing

Problem:
Retraction settings setup incorrectly

Solution:
Adjust retraction distance to proper settings allows the extruder to travel between parts without stringing

Case Study:
Support Material

Problem:
Support material did not stick to the print surface, minimal surface contact did not allow the material to adhere properly

Solution:
Increasing the number of skirts allows the support to build from a single layer of material as a base

Case Study:
Underextrusion

Problem:
Extrusion multiplier set too low, under-extrusion occurs when the extruder does not supply enough material as fast as it is needed

Solution:
Increase the extrusion multiplier, raising the print temperature results in better material flow to prevent under-extrusion

Case Study:
Warping

Problem:
The material creates tension on the thin features of the part as it cools and begins to pull away from the print surface

Solution:
Reduce the infill percentage, the internal tension can be relieved, add a brim to the part to givee the thin features more surface contact

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