We used to have the same problem with our Form 1. Two out of three prints were a fail and the results we had were similar to what I can see in your pictures.
The problem went away after we sent the print to be upgraded. The upgrade also includes a recalibration and that is where I suspect the problem lies. Try looking through the calibration information on their website, they also have an interesting video tutorial that I cannot find right now.
I have had this same problem as well. I was printing a larger piece and it got through 75 percent and the rest was on the bottom of tray. I added more supports and it printed perfect after that. Hope this helps. Good luck!
Well, the fact that the supports print so nice and you used a new tank and different resin at least tells you there is nothing wrong with the printer.
If you don’t find the problem and you can’t upload the model, post a screenshot of the cross section (layer) where the printing of the model starts failing.
PS: you shouldn’t place models on the build platform like that - even if they print, the strain on the mechanics and tank will be much higher than with supports.
The reason I printed the cube directly on the bed was that the removement of the support is quite tedious and i had to ship 50 pcs, I considered this a good idea (spoiler all cubes where fine). Additionally the support generated would be consume as much resin as the cube itself.
Which raises another general question to me, since 3D Hubs cant calculate the volume of the needed support how do you the pricing? simply assuming some percentage offset, hoping it doesn’t need more? I already have trouble, due to failures of such a simple looking model
But anyway thanks for the hint on the strain! could you please add more detail to you explanation? since i can’t imagine why there should be less strain if printing with supports and the same orientation. it has to peel it off anyway?
-I always add costs for support to orders. Haven’t had a customer reject his order because of the added cost. I agree that this should be fixed or at least there should be a way to inform the customer that there will be added cost. The other option is to jack up your ml price but that doesn’t help if the customer compares prices.
-Supports help take some strain off the peeling process because they allow the platform-part-tank to move in x/y a bit, so they take the initial hit before the part peels of the tank - otherwise these forces will work against the peeling mechanism, your platform and the tank / PDMS layer. If you watch it print a larger cross section you may notice that your platform slightly tilts on peeling, together with the tank - when you print directly on the platform, the platform and the tank are basically glued together and nothing can move in x or y - but it wants to shift a bit, and that force now goes to the T-rail, tank and platform (and your print)
Also when placing objects flat on the tray, you usually printing the largest cross section through the whole print (the cube is an exception obviously)
I also tried to print objects directly on the platform, cause I wanted to save resin and have nice surfaces, but out of 3 different parts, only one printed right.
Lastly, Formlabs themselves state that you should always use supports - although one might argue this is because they like to sell the juice for those supports
For me, the thinking goes like that: A failed print means wasted juice, wasted time cause I have to filter the resin, potentially a wasted tank because of clouding and I have to start all over with the print. If I can avoid one failed print in 20 by placing supports, it’s worth it to me - especially cause I make the customer pay for the supports.
On another note, place objects near the hinge side of the tank to reduce the strain on the peeling stepper / threaded rod. You will have more lever -> less force needed.
