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Fine Layers (0.06mm) and clogs with the Titan Aero

12/24/2018

2 Comments

 
Picture

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I was attempting to print the above model at 0.06mm layer height on my Ender 3, which is set up with a Titan Aero.  The problem shown in the right side pic is that the filament got ground down and it stopped extruding correctly.  The filament grinding however seems like it is probably a symptom since I have not had this problem running the same PLA at 0.2mm layer heights (and have run several prints with it with the same tension in the extruder).  After some searching, I found a post which described how retraction is the likely problem:

https://www.thingiverse.com/groups/prusa-i3/forums/general/topic:9008

So I now suspect the problem with the above print is due to heat creep, thanks to the lower flow with the shorter layers the heat likely has time to build up in the heat tube.  To try and remedy this, I have set the retraction down to 0.8mm as a test (this is probably where it should have been for PLA based on what I have read online).  Additionally I dropped the retraction speed to 30mm/s (from 40), and dropped the temps for this MakerGeeks PLA (pearl green or something) which is recommended to run at the very hot 235, turned down to 232.  Will see how the next try goes...

Changes:
Retraction Distance 0.8mm (was 1.8mm)
Retraction Speed 30mm/s (was 40mm/s)
Printing Temperature 232 (was 235)
Increased the tension by about 1/3 turn of the knob on the extruder

Update - below is the result with the above settings, seems that it was running good for most of the print, but then seems to have experienced heat creep when the legs started to merge (or probably more likely due to the narrowing of the top side model which started at the neck).  Nice that stringing was not too bad with this config except on the supports:
Picture
Next up, will try these:

Retraction Distance 0.6mm (was 0.8mm)
Retraction Speed 25mm/s (was 30mm/s)
Printing Temperature 230 (was 232)

Update - well that didn't work to well:
Picture
Next up, will try these:

Retraction Distance 0.5mm (was 0.6mm)
Retraction Speed 25mm/s (was 30mm/s)
Printing Temperature 234 (was 230) - went back up with the temps, seems that 230 may have been too cold

I also tightened the extruder thumbscrew another 1/2 turn.

And POW, that did it, the model however did not look too great scaled down even printed at 0.06mm LH, so not sure I can use it (still debating and may give it a shot of primer to see how many details show up).  Looking at the settings, it appears this was probably run at 60mm/s, where I normally use 40mm/s, so I think if I ran it at slower speed, the fingers would look better.
Picture

Quick update - had some more of the same problems with another print that was running at 0.1mm LH, and the fix seems to have been to drop the retraction further (hard to believe 0.1mm really could make a difference, though it was the only thing I changed):

Retraction Distance 0.4mm (was 0.5mm)
Retraction Speed 25mm/s
Printing Temperature 234

2 Comments
Timothy Major
7/8/2020 08:49:37 am

wondering if you had any further issues or if you settled in on a good set of settings.

Reply
Mike link
8/8/2020 05:11:12 pm

Hi, Sorry I missed your comment, was just checking today and saw it. The Aero is printing like a champ now. Part of the problem may have been the filament. But I had a number of issues with the Titan though as well and swapped the bearings, added more cooling (bigger fan) and also modified my cooling duct for the parts cooler. I also replaced the small piece of bowden that goes from the heatbreak to the plastic part inside the Aero and made sure it was correctly sized. Overall though, I think the aero is decent and works now, it just was a combination of several problems.

Reply



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