The biggest thing I see is that you’d want to look at hollowing the model. Reducing the surface area at each layer decreases the tension during the peel step. I’ve been using Meshmixer for this step.
Additional option specifically for this piece would be to cut out the lower jaw and print it separately. The orientation of the model likely led the unsupported jaw piece to get torn off.
From my personal experience, the Grey Resin is a bit more finicky than Clear. The pigment settles and the opaque nature of the liquid makes it harder to fish out failed bits from the tank.
This looks like a typical " lack of enough supports" fail. If a build layer fails to stick to the model and remains attached to the vat, it will grow the failure out. Each build layer around the piece attached to the vat will continue to fail and produce a roughly conical build error in the part…
Been there and it happens.
Check vat for “sediment” and try a different orientation, more supports too…
Id like to go with Tobias his trouble shoot this will probebly work, taken in account that the peeling proces of the form 1 an + is a physical proces its likley the cause of the failed print. The less stress on the physical peel the better the result! its hard to judge but you wil get a feel for it when you keep on printing more and more.
Did you used internal supports ? make sure that you check your layers carefully in the slicer and manually ad support if suspiciouse don’t save to much on supports there there for a reason! If there is residu of the failed layers in the vat make sure you filter the resin with a panty hose (that is what i’m doing when things like this happen) flakes in your resin compromises prints when continuing with residu
There could be several reasons why the jaw didn’t form. I’ll start with Orientation.
Orientation is always important with the Form1 and Form 1+.
I have had the most success when I orient the part with the largest cross section thickest region of the part closest to the build platform and the smallest details furthest away from the build platform.
The largest cross section/thickest region of the part should be furthest away from the hinge side of the build platform.
The part should be oriented along an axis perpendicular to the hinge side, so if there is a long side to the part it should be perpendicular to the hinge side of the build platform.
Resin: The resin could be old or maybe there are partially cured blobs that need to be filtered out (fine mesh paint filter should work)
Mirrors: Carefully wipe the large mirror, as per instructions on FormLabs web site.
Temperature: did the temperature fluctuate, i.e. get much colder during the printing process? If it gets too cold the resin flows less easily then it is intended too.
Resin Tank: is it cloudy anywhere in the PDMS layer? This can happen after 1-2 bottles of resin. There is some discussion about using a surficant (spelling?) called Rain-X in the US, that is claimed by some Form 1+ users, to inhibit the clouding.
I am almost forgot to ask if your part is hollow/shelled. This is important as it is creates less physical stress on the material during printing, so there are fewer chances of a print fail. (I didn’t read all of the comments).
Same advice as Joe. However, I doubt its dust on the mirror since the rest of the print looks pretty good.
The “suction” problem sounds like it could be feasible also. Turning the print a little more on its side might take care of that one.
Scroll through the print layers in PreForm to see if you have any islands or really thin overhangs near the layers where it failed. Make sure you click the “internal supports” box and manually add supports to the area that failed and any areas with islands or overhangs. PreForm is pretty good about turning problem areas red but it misses problem areas from time to time.
The chances of print fails go way up after you have run around a half liter or more of resin through a tray. Sometimes the trays don’t last very long before prints start sticking. That’s a function of how many peals and lazes different areas of the tray has seen and what layer resolution you are using.
Also, not in this case but in general, the taller your print the more likely it is to fail since supports can’t always hold the print rigidly enough to ensure they peal from the tray at the layers further away from the build plate.
Post up if you find out what the actual culprit was.
I’m pretty impressed at that Ultimaker2 print. That’s really top notch quality for a FDM printer.
First of all, you need to go to the formlabs user forum - it’s a must if you own a form 1. The reason for that failure looks to me to primarily have been caused by printing your model solid (or very thick). Prints on the form1 or form1+ should be hollow if possible, with a ‘shell’ around1.5mm - 3mm thick. FDM printers like the ultimaker don’t care if the model is hollow or not, that’s not the case with the form1/1+. So, basically what everyone else has said!
Sometimes prints can just fail like that due to bad luck, I’ve had a print fail like that only to work fine the 2nd time. Check for dust on the mirror and tray bottom as even a small amount of dust could weaken a single area so that it doesn’t cure properly and rips away, and subsequent layers on that spot stick and over cure which slowly brings adjacent layers with it.
Hi, this usually happens when the printing layers have no time to cool down.
There are 2 things you can do to fix this:
1. Cooling. Add a fan that blows cool air on the print. Lots of people print a fan duct to add a stream of air on the print object. Look at thingyverse, lots of air duct models.
2. Add another model(s). Now the extruder head has to travel between multiple objects. That creates time for a layer to cool down and settle before the next layers is printed.
I did not read all of the replies so this may be a repeat.
1. did you orient it or let the software orient it?
2. were there any red areas on the print preview with supports created?
3. Hollowing is probably not your problem as the rest of the build went fine.
4. Look at the bottom of the tray after it is cleaned out to see if it has gotten cloudy. This could have happened during the build where it might have gotten to a tipping point. I say this because you said you had you did previous builds and they turned out okay.
5. Was a hard blob let in the tray?
I think the biggest problem is probably the orientation since you said you laid it flat on its back which might have caused that part of the jaw to have unsupported areas.
Features like jaws, ears and noses are inherently overhang features, you should start assessing print failures by considering how it was orientated and supported.
I just have to say, I’m absolutely overwhelmed with the amount of help and advise I got in 24 hours! Thank you guys so much. I’ll keep all your feedback in mind and try again soon!
