Random Layer Separation - Suggestions?-

[bigredmachine_88]

I've printed 100+ of this particular model on my P1S flawlessly and now all of a sudden I am getting a random layer separation on roughly 1 out of every 3 prints. The separation generally occurs at the halfway point, but occasionally it happens in the lower 1/3rd of the print. Some things to note:

• Tuned filament and printer profile (no changes made in the past 60+ prints)
• Rods cleaned and lubed
• Belt tension is good
• Printer re-calibrated
• Printing from the external spool holder
• A quality filament that I utilize extensively (has been dried)
• There is nothing of concern showing in the slicer preview at the separating layers (Orca Slicer)
• There is a support tower surrounding this model. The separation very rarely also translates into the support
• Only print in PLA and PETG

Suspected culprit(s):

• Filament snagging/binding on the spool, causing a random/momentary poor feeding into the extruder
• Something not running smoothly in the z-direction (steppers skipping?)
• Feed gear slipping/skip?

[VidJunky]

How old is your filament?

It doesn't sound like it happens in the same spot every time, this would count out a bad slice or something related to the sliced file code. My first thought is moisture. Quality filament absorbs moisture just like the cheap stuff I use. Add to that PTE is a moisture magnet by nature. Don't know about PETG, I tried it, failed and moved on, but plastic in general absorbs moisture. Do you have any way to dehydrate your filament? I would recommend that before saying to open a new roll of filament but that would be next.

On personal note I had this experience. I was trying to print something and wanted to use this older roll of filament to use it up. After a few failed prints I ended up not having enough to use anymore of that roll and opened a new one. I could see the difference from the first line to the end of the first layer. No issues with that print.

Anyway, I also asked Google and Gemini says,

Random layer separation in 3D prints, also known as delamination, can be caused by a variety of factors, including insufficient layer adhesion, temperature issues, and even mechanical problems with the printer. To address this, consider checking print temperature, layer height, cooling, and material flow, as well as ensuring proper extruder mechanics. [1, 2, 3]
Here's a more detailed breakdown: [4, 4, 5, 5]
1. Temperature and Layer Adhesion: [4, 4, 5, 5]

• Insufficient Heat: If the print temperature is too low, the molten plastic may not fully adhere to the previous layer, leading to separation. [4, 4, 5, 5]
• Over-Cooling: Rapid cooling, especially with fans, can cause layers to shrink and separate before they fully bond, says All3DP. [2, 2, 6, 6, 7]
• Temperature Discrepancies: Uneven temperatures across the print bed or hot end can also lead to inconsistent layer bonding. [1, 1, 4, 4]

2. Layer Height and Material Flow: [8, 8]

• Too High Layer Height: If the layer height is too large, the new layer might not have enough contact area to properly adhere to the previous layer. [4, 8]
• Under-Extrusion: Not enough material being extruded can result in weak bonds between layers, as the new layer doesn't fully "squish" into the previous one, according to a Reddit post. [6, 6, 9, 9]
• Over-Extrusion: Too much material can cause the new layer to push the previous layer off, resulting in separation. [9, 10, 10]

3. Mechanical Issues: [3, 3, 9, 9]

• Extruder Problems: Issues like a clogged nozzle, binding filament, or low extruder tension can lead to inconsistent material flow and layer adhesion. [3, 3, 9, 9]
• Z-Axis Problems: Skipping or uneven movement in the Z-axis can also contribute to layer separation. [3, 3, 11, 11]
• Filament Quality: Moisture in the filament can cause issues with melting and adhesion. [12, 12, 13, 14]

4. Slicer Settings:

• Combing Settings: Settings like combing in slicer software (Cura) can cause issues if they're not configured correctly. [3]

Troubleshooting Steps: [5, 5, 15, 15]

1. Increase Print Temperature: Try increasing the hot-end temperature in small increments (e.g., 5°C) until you see improvement. [5, 5, 15, 15]
2. Reduce Layer Height: If the layer height is high, try decreasing it to improve layer bonding. [8, 8]
3. Calibrate Your Printer: Ensure your printer's bed is level and the extruder is properly calibrated. [3, 3, 11, 11, 16, 17, 18]
4. Check Filament: Make sure your filament is dry and properly loaded into the extruder. [12, 12, 19]
5. Adjust Cooling Settings: If using fans, try adjusting the cooling speed and/or distance from the print. [15, 15, 20, 20, 21]
6. Inspect Extruder: Check for clogs, binding, and low tension in the extruder. [3, 3, 9, 9]
7. Review Slicer Settings: Examine combing and other settings in your slicer software. [3, 3]

This video will help you diagnose and fix layer shifts in your 3D prints: https://www.youtube.com/watch?v=9VFpXUXgyJ8