Problems Printing Large 90 Degree Overhang With ABS

[pbprinting]

So I am trying to print this part that has a roughly 2 inch 90 degree overhang with my flashforge creator pro in ABS. The print is a 20 hour print and it totally messed up at the 10 hour mark. It seems that when printing the overhang the overhang layer did not stick to the supports. There was drastic lifting which lead to a spaghetti wad in the corner with a completely failed print. If needed I could provide the STL file assuming my client is ok with this.

For now my idea is to reduce the 90 degree overhang into 45 degree overhangs instead. I will place the object on the edges that make up the 90 degree overhang. My only worry is that I have less surface contact with the build plate. Since I am dealing with ABS I will use a brim but I am still worried warping will lift the contact points.

Perry

[SOC3D]

Hey Perry, Can you post your support settings and basic print settings layer height infill etc? Also what slicer are you using?

[pbprinting]

Hello Miaviator,

I am using Simplify 3d as slicer and here below are the settings you requested:

Printer Type/Model: FlashForge Creator Pro (2016 model)

Support Settings:

Infill: 30%

Extra Inflation distance: 0.00 mm

Dense Support Layers: 1

Dense Infill Percentage: 70%

Print Support Every: 1 layers

Seperation from Part,

Horizontal Offset from part: 0.00 mm

Upper Vertical Seperation Layers: 1

Lower Vertical Seperation Layers: 1

Automatic Placement,

Support type: Normal

Support Pillar Resolution: 1.00 mm

Max Overhang angle 40 deg

---------end--------------------

Layer Settings:

Layer height: 0.3 mm

6 top and bottom layers

3 perimeter shells

First Layer Settings:

First Layer Height: 90%

First Layer Width: 100%

First Layer speed: 50%

------end ----------------------

Infill settings:

Infill pattern: Full Honeycomb

External Fill Pattern: Rectilinear

Interior Fill Percentage: 10%

Outline Overlap: 60%

Infill Extrusion Width: 100%

Minimum Infill Length: 5.00 mm

Print Sparse Infill Every: 1 Layers

-------------end---------------------

Additions:

Use Brim is set all other options (raft, ooze shield, prime pillar) are not

Skirt layers: 1

skirt offset from Part: 0.00 mm

Skirt outlines: 25

-----------------end---------------------

Temperature:

Extruder temperature: 235 degrees

Heated Bed Temperature: 110 degrees

--------------end--------------------------

Cooling:

set fan to 100% on 25th layer

Speed overrides:

Adjust printing speed for layers below 15 sec allow speed reduction down to 20%

-----------------end -----------------

Other (Speed settings):

Default printing speed: 3600 mm/min

Outline Underspeed: 50%

Solid infill underspeed: 50%

Support Structure underspeed: 50%

x/y axis movement speed: 3600 mm/min

Z Axis movement speed: 1200.00 mm/min

---------------end----------------------

Hopefully this will provide you with enough information about my setup.

Perry

[SOC3D]

Can you attach or send me the factory file? miaviator(at)miaviator.com I can take a look and make some changes and send it back to you.

[pbprinting]

Ok I sent the factory file to your email address.

[MindFuLL]

A picture of the failed print would be very helpful. First place to start when dealing with overhangs is getting the temp tuned for your material. You want it just hot enough and no more. Also, I don’t know what software you are using but you should be able to reduce the contact distance between the support and part which may also help. Most importantly I would find/make a design with a similar overhang to test and get dialed in before doing one that required 10 hours of printing before you find out if you solved the problem.
-Jesse