Overhang Test Print

As soon as I had my printer out of the box, I went hunting on Thingiverse for a torture test print. I ended up with this one: http://www.thingiverse.com/thing:40382/#instructions.

I scaled it down (0.4 - all axes) and printed it with the "Stock" settings: Z-ABS, .19 layers, Light infill, 20deg support, 20 percent fan.

The first 5 test angles (20deg through 40deg) printed flawlessly, with no supports.

The last test angle (70) printed flawlessly because it used support. It was the only one with support.

The ones in the middle, all distorted slightly. Interestingly, the distortion is on the side of the overhang that is away from the fan (opposite of the fan).

The only other thing of note, is that I am surprised that the top flat surface isn't smoother.

I suspect that by tweaking a few things (fan, support, orientation), it could print much better than this. I'd love to hear what other people think.

-J

Distortions are caused by ABS curling. Try printing the same thing but give 80-100% power of the fan blowing. This should help.

So, I re-oriented the piece so that the overhangs were pointed at the fan. Also, I increased the fan to 100% and eliminated the supports.

 

I must say - I’m pretty impressed! All of the various angles printed cleanly.

The only real issue regarding overhangs is about the small (&curved) ones - they seem to never come out right.

I've printed the full scale test, came out fine - I'll post pics and details as soon as I can.

http://i58.tinypic.com/14lj4fq.jpg

http://tinypic.com/r/sbt0cg/8

http://tinypic.com/r/1ranw9/8

The test: http://www.thingiverse.com/thing:40382

0.19, light, 0 support, 0 additional fan, 3rd party ABS, with enclosure:

http://tinypic.com/r/2saf6fb/8

http://tinypic.com/r/2s81qah/8

http://tinypic.com/r/2wcmm3t/8

Not a real 1 on 1 comparison, as I've printed it full size.

I did quite the opposite: higher temperature due to enclosure and no extra fan help. Looks good, considering that the thing doesn't even stand upright by itself (numbers side up).

I'll say that both our results are better than 'industry standard' - up to ~50 degrees clean overhang is more than ok.

It's a shame, though, that the really annoying thing - see the first 3 pics - is not solved yet.

Here is my testprint on my UPmini, way better than ultimaker, makerbot and I even dare to say Zortrax.

Attachment 38 not found.

Here is my testprint on my UPmini, way better than ultimaker, makerbot and I even dare to say Zortrax.

attachicon.gifDSCN2404zx.jpgattachicon.gifDSCN2408zx.jpg

How does it look like with Fortus 400 ? ;)

Here is my testprint on my UPmini, way better than ultimaker, makerbot and I even dare to say Zortrax.

attachicon.gifDSCN2404zx.jpgattachicon.gifDSCN2408zx.jpg

I wouldn't say better than Zortrax.. Close to Zortrax maybe. :ph34r: ..v8ug.jpg

How does it look like with Fortus 400 ? ;)

The Fortus 400 is uncapable of doing such a test like this without a lot of tweaking on the toolpaths wich will lead to differences between one layer diameter and the next.

I have done the famous torture test done on make magazine 2 years ago and well even if you can disable support generation that machine is not designed to work without support, hence it's not capable of overhangs etc, etc.

Thus the high quality it's even slower than most printers but the quality is assured.