Any ideas what might cause this? (Bridging problem)

I printed this HALO iphone 6 case in glowfill, face down (smooth areas were face-down on glass), and during the bridging process, none of the lines fused together... just strings. The rest of the phone came out nicely and is solid with the lines being well fused and no delamination, it's just the bridging part that didn't come out right. Has anyone seen this issue before and do you know how to fix it? Many thanks.

I'm using a CTC with a replicator 2x carriage, replicator 2x alu-dual cooling bar upgrade, and threaded thermal barriers. It also has an active cooling fan. Click on the picture to zoom in:

Attachment 6052Attachment 6051

Makerware settings:

{
"comment" : [
"This is a custom profile for MakerBot Slicer. Editing it will modify your",
"slice settings. For documentation on MakerBot Slicer parameters, see here:",
"http://www.makerbot.com/support/makerware/documentation/slicer"
],
"version":"2.4.0",


"layerHeightMinimum": 0.12,
"layerHeightMaximum": 0.27,


"layerHeight": 0.20,
"layerWidthMaximum": 0.4,
"layerWidthMinimum": 0.4,
"layerWidthRatio": 1.481481,
"bedZOffset": 0.0,
"startX": -110.4,
"startY": -74.0,
"startZ": 0.2,
"defaultExtruder": 0,


"rapidMoveFeedRateXY": 100,
"rapidMoveFeedRateZ": 23,


"minLayerDuration": 5.0,
"minSpeedMultiplier": 0.3,


"doDynamicSpeed": true,
"dynamicSpeedCurvatureThreshold": 15,
"dynamicSpeedDetectionWindow": 3.0,
"dynamicSpeedSlowdownRatio": 0.3,
"doDynamicSpeedGradually": true,
"dynamicSpeedTransitionWindow": 6.0,
"dynamicSpeedTransitionShape": 0.4,
"doDynamicSpeedOutermostShell" : true,
"doDynamicSpeedInteriorShells" : false,


"doSplitLongMoves": true,
"splitMinimumDistance": 0.4,


"extruderTemp0": 200,
"extruderTemp1": 200,
"platformTemp": 64,


"numberOfShells": 2,
"infillShellSpacingMultiplier": 0.7,
"insetDistanceMultiplier": 1.0,


"roofThickness": 0.8,
"roofLayerCount_disabled": 4,
"roofAnchorMargin": 0.4,
"floorThickness": 0.8,
"floorLayerCount_disabled": 4,


"coarseness": 0.0001,


"sparseInfillPattern": "hexagonal",
"infillDensity": 0.5,
"infillOrientationOffset": 0,
"infillOrientationInterval": 90,
"infillOrientationRange": 90,


"gridSpacingMultiplier": 0.99,
"solidFillOrientationOffset" : -45,
"solidFillOrientationInterval": 90,
"solidFillOrientationRange": 90,


"doBacklashCompensation": false,
"backlashEpsilon": 0.05,
"backlashFeedback": 0.9,
"backlashX": 0.0,
"backlashY": 0.09,


"doBridging": true,
"bridgeAnchorMinimumLength": 0.8,
"bridgeAnchorWidth": 0.8,
"bridgeMaximumLength": 80.0,
"bridgeSpacingMultiplier": 1.0,


"doExternalSpurs": true,
"doInternalSpurs": false,
"maxSpurWidth": 0.5,
"minSpurLength": 0.34,
"minSpurWidth": 0.12,
"spurOverlap": 0.001,


"doRaft": false,
"defaultRaftMaterial": 0,
"doMixedRaft": false,
"raftAligned": true,
"raftBaseAngle": 0,
"raftBaseDensity": 0.7,
"raftBaseLayers": 1,
"raftBaseRunGapRatio": 0.8,
"raftBaseRunLength": 15.0,
"raftBaseThickness": 0.3,
"raftBaseWidth": 2.5,
"raftInterfaceAngle": 45,
"raftInterfaceDensity": 0.3,
"raftInterfaceLayers": 1,
"raftInterfaceThickness": 0.27,
"raftInterfaceWidth": 0.4,
"raftModelSpacing": 0.21,
"raftOutset": 4,
"raftSurfaceAngle": 0,
"raftSurfaceLayers": 2,
"raftSurfaceThickness": 0.27,


"doPurgeWall": false,
"purgeWallModelOffset" : 2.0,
"purgeWallSpacing" : 1.0,
"purgeWallWidth" : 0.5,
"purgeWallBasePatternWidth" : 8.0,
"purgeWallBaseFilamentWidth" : 2.0,
"purgeWallBasePatternLength" : 10.0,
"purgeWallPatternWidth" : 2.0,
"purgeBucketSide" : 4.0,
"purgeWallXLength" : 30,


"anchorWidth": 2.0,
"anchorExtrusionAmount": 5.0,
"anchorExtrusionSpeed": 2.0,


"doSupport": false,
"defaultSupportMaterial": 0,
"doMixedSupport": false,
"doSupportUnderBridges": false,
"supportAligned": true,
"supportLeakyConnections": true,
"supportDensity": 0.2,
"supportExtraDistance": 0.5,
"supportAngle": 68.0,
"supportModelSpacing": 0.4,
"supportExcessive": false,


"doFanCommand": true,
"fanLayer": 2,
"weightedFanCommand": -1,
"doFanModulation": true,
"fanModulationWindow": 0.1,
"fanModulationThreshold": 0.5,


"doPrintProgress": true,


"startGcode": "",
"endGcode": "",


"commentClose": "",
"commentOpen": ";",


"extruderProfiles": [
{
"bridgesExtrusionProfile": "bridges",
"feedDiameter": 1.72,
"feedstockMultiplier": 0.99,
"firstLayerExtrusionProfile": "firstlayer",
"firstLayerRaftExtrusionProfile": "firstlayerraft",
"infillsExtrusionProfile": "infill",
"insetsExtrusionProfile": "insets",
"nozzleDiameter": 0.4,
"outlinesExtrusionProfile": "outlines",
"raftBaseExtrusionProfile": "raftbase",
"restartExtraDistance": 0.0,
"retractDistance": 1.3,
"retractRate": 25,
"toolchangeRetractDistance" : 19.0,
"toolchangeRetractRate" : 6.0,
"toolchangeRestartDistance" : 18.5,
"toolchangeRestartRate" : 6.0
},
{
"bridgesExtrusionProfile": "bridges",
"feedDiameter": 1.72,
"feedstockMultiplier": 0.99,
"firstLayerExtrusionProfile": "firstlayer",
"firstLayerRaftExtrusionProfile": "firstlayerraft",
"infillsExtrusionProfile": "infill",
"insetsExtrusionProfile": "insets",
"nozzleDiameter": 0.4,
"outlinesExtrusionProfile": "outlines",
"raftBaseExtrusionProfile": "raftbase",
"restartExtraDistance": 0.0,
"retractDistance": 1.3,
"retractRate": 25,
"toolchangeRetractDistance" : 19.0,
"toolchangeRetractRate" : 6.0,
"toolchangeRestartDistance" : 18.5,
"toolchangeRestartRate" : 6.0
}
],
"extrusionProfiles": {
"bridges": {
"feedrate": 40,
"temperature_disabled": 230.0
},
"firstlayer": {
"feedrate": 30,
"temperature_disabled": 230.0
},
"firstlayerraft": {
"feedrate": 50,
"temperature_disabled": 230.0
},
"infill": {
"feedrate": 90,
"temperature_disabled": 230.0
},
"insets": {
"feedrate": 90,
"temperature_disabled": 230.0
},
"outlines": {
"feedrate": 40,
"temperature_disabled": 230.0
},
"raftbase": {
"feedrate": 10,
"temperature_disabled": 230.0
}
}
}

that looks interesting - but how does it answer the question ? lol

I'm guessing it's been modified to do something to the bridging. But evena couple of words of explanation might help. Also we don't know he's using makerware.
Given that I've succesfully bridged 51mm gap with the stock makerware settings - don't think that's the issue here. Makerware does bridging really well. The second item I ever printed from makerware was a secret heart box. Came out brilliantly. And the top is all bridging.

So the questions we do need answered :-)
What slicer.
what filament
what print temp and what print speed.

Mind you that said - the prints look pretty good to me :-)

I'm using version 2.4 because 3.6 doesn't want to work on either of my laptops. Just won't slice and it will say error slicing on any object. Are there significant improvements in the newer versions that I'm missing out on?

no :-)

How many layers did you set ?
2 would be a minimum I'd recommend.

so that's one question answered - any reason you're keeping the rest a secret ;-)

Nothing was ever a secret, the second post that starts with "Makerware settings:" is the settings I used to print it. Anyways it was printed with glowfill, with 2 shells, with dynamic speed on. The speed when not extruding was 100, infill and insets was at 90, and outlines at 40, and bridges at 40. Print temp was 200 with the bed at 64. I was looking at the settings just now, and I was wondering if I could trick it into laying very thin many lines for bridges, instead of just a few thick lines. Maybe I could change the nozzle size setting under the bridges extruding profile or some other setting.