Common Problems and Solutions
This appendix contains a quick reference guide for many of the common problems you may encounter when using 3D printers. Tables A-1, A-2, A-3, and A-4 provide descriptions of problems, sources of the problems, and solutions. I have divided the categories of problems into sections for easier reference.
The best way to use these tables is to look for the problem description that best matches the problem you are experiencing, identify which of the possible sources apply, and then execute the remedy lists. Note that there can be more than one remedy per problem and source. Further, some problems may be remedied by changes to hardware or software. It is best to test each solution one at a time. Some remedies may be worded such that you can repeat the action. For example, lowering the hot-end temperature by 5 degrees can be applied repeatedly until the problem is solved.
Tip Well, there is a limit to this. Clearly, reducing the temperature a dozen times by 5 degrees would likely be excessive. The same is true with raising the temperature. In either case, you will reach a threshold where the process is no longer applicable. Use these techniques as a guide rather than a literal instruction.
This category of problems includes those that relate to how the object adheres to the build plate, as well as other layer adhesion problems.
Table A-1. Adhesion Problems and Solutions
Problem |
Cause |
Solution |
|---|---|---|
| Objects lift on one side or at corners on one side. The object is adhered well on other sides. | Bed not level | If the bed is not level, the side that is lower can induce lift. Check and re-level the print bed. |
Use a raft. | ||
| Draft or air currents | Use walls (blue tape, printed) to control slight air currents. | |
Move printer away from vents, open windows and other sources of air currents. | ||
Place printer in an enclosure or investigate the possibility of adding a hood and doors. | ||
| Object is not sticking to print surface or comes loose during printing. | Z-height too high |
Check and set Z-height lower. |
Heated bed too cold |
Raise temperature of heated print bed by 5 degrees. | |
| Print surface dirty or worn | Clean print surface. Inspect for damage and replace if worn or you have used it for more than 10 prints in the same area. | |
Use a raft. | ||
Use a brim. | ||
First layer print speed too high |
Slow the first layer speed. Slower first-layer print speeds can help first-layer adhesion. You should not lower the first layer speed to less than 75% of the normal print speed. | |
Hot end too cold |
Raise the temperature of the hot end by 5 degrees. | |
| Object lifts on several sides or in several places around the perimeter. | Heated bed too cold |
Raise the temperature of heated print bed by 5 degrees. |
| Strong air currents or drafts | Turn off all fans and HVAC vents, and close windows and doors. | |
Use an enclosure or add a hood and doors to block air currents. | ||
Ambient temperature too cold |
Increase ambient temperature. Best to keep it stable during printing. | |
Object has very thin protrusions |
Add helper disks to increase surface area that contacts the print surface. Some slicers have an option for this feature. You can always add them using the .stl mashup procedure described in an earlier chapter. | |
| Object cracks at higher layers. | Strong air currents or drafts | Turn off all fans and HVAC vents, and close windows and doors. |
Use an enclosure or add a hood and doors to block air currents. | ||
Ambient temperature too cold |
Increase ambient temperature. Best to keep it stable during printing. |
This category of problems includes those related to the extruder, hot end, and filament.
Table A-2. Extrusion Failures
Problem |
Cause |
Solution |
|---|---|---|
Filament jams in extruder or extruder drive pulley/bolt strips filament |
Hot end too cold Contaminated filament |
Raise hot end temperature by 5 degrees. Check filament for damage or stress (filament will show lighter color) and remove damaged section. Check for dusty or dirty filament and clean filament with a lint-free cloth. Use a filament filter to remove dust and small debris. If failures continue, discard filament (or return to vendor for partial refund). |
Nozzle obstruction |
Remove nozzle and clean it using the cold pull method. Remove any obstructions on the build platform. | |
Wrong nozzle size |
Check your slicer settings. If your slicer settings have a value that is too low, the extruder can jam by pressing more filament through the hot end than it can handle. | |
Too much tension on spool |
Make sure spool can feed with as little friction as possible. Use a spool holder with rollers or bearings for smooth movement. | |
Wrong tension on extruder door or clamp |
Check and adjust tension. Too much tension can cause the filament to compress. Too little tension can permit the filament to slip. | |
Filament curls when exiting hot end |
Damaged nozzle |
Check the nozzle to ensure there is no debris, burr, or other damage to the opening. Replace the nozzle if damaged. |
Burning smell from extruder |
Hot end too hot |
Lower hot end temperature by 5 degrees. |
Filament oozes excessively from hot end |
Hot end too hot |
Lower hot end temperature by 5 degrees. Note: Some oozing is normal, but it should not run out like the extruder is running. |
Filament extrudes unevenly |
Hot end too cold Extruder stepper motor overheating Extruder stepper motor current too high Extruder stepper motor current set too low |
Raise hot end temperature by 5 degrees. Check stepper driver current and adjust to match stepper motor. |
Loose, stripped, or worn gears |
Tighten loose gears and set screws. Replace worn or broken extruder gears. | |
Popping or spitting noises when printing |
Contaminated filament |
Filament may have too much moisture. Use a drying agent to dry the filament for at least 24 hours. |
Steam from hot end |
Contaminated filament |
Filament may have too much moisture. Use a drying agent to dry the filament for at least 24 hours. |
This category includes problems you can encounter that cause print quality to suffer.
Table A-3. Print-Quality Issues
Problem |
Cause |
Solution |
|---|---|---|
| Object layers break apart or appear thin and weak | Wrong nozzle size |
Check your slicer settings and choose the correct nozzle size. |
Wrong filament size |
Measure your filament and ensure the correct size is specified in your slicer. | |
| Slight variances in layer alignment | Loose or worn belts on axis |
Adjust belt tension. |
| Loose frame components | Tighten loose bolts. Use lock washers or Loctite (blue) to keep bolts and nuts from coming loose from vibration. | |
Reduce print speed to reduce vibration. | ||
Object appears squished and smaller (Z axis) than desired |
Heated bed too hot |
Lower heated print bed by 5 degrees. |
Object has thick runs of filament |
Too much filament extruded |
Check diameter of filament and change slicer settings to match. |
Blobs and clumps |
Too much filament extruded |
Check diameter of filament and change slicer settings to match. |
Holes slightly too small |
Too much filament extruded |
Check diameter of filament and change slicer settings to match. |
Circular areas oblong |
Loose or worn belts on axis |
Adjust belt tension. |
| Object layers shift in one direction | Loose or worn belts on axis |
Adjust belt tension. |
Stepper motor failure |
Check stepper driver voltage. If correct, replace stepper motor. | |
Stripped belt drive gear |
Replace belt drive gear. | |
Acceleration too high |
Lower acceleration parameters in firmware. | |
Obstruction in axis movement |
Remove obstruction. | |
Plastic part failure |
Check all axis parts for damage and replace as needed. | |
Damaged bearings |
Check all bearings for proper lubrication and replace loose or worn bearings. |
Mechanical or Electrical Problems
This category includes a host of mechanical and electrical failures that can cause any number of print failures. Some are severe. Always use caution when working with electronic components and especially mains power.
Table A-4. Mechanical and Electrical Failures
Problem |
Cause |
Solution |
|---|---|---|
| Printing pauses or halts while printing | Loss of communication with computer |
If printing from computer, check USB connection. |
Corrupt SD card/file |
Check SD card for corrupted files. Replace SD card or replace corrupt file. | |
| Overheating electronics | Mount fans to cool electronics. | |
Check stepper driver for correct voltages. | ||
| Hot end or heated print bed stops heating | Heating element failed |
Replace heating element. |
Electronics board failure |
Replace electronics board. | |
Power supply failure |
Check power and replace if no power to electronics. For example, it is possible for the 12v power to fail, making motors and heaters inoperable. | |
Broken wire |
Check all wiring for stress fractures and loose connectors. Replace as needed. | |
Blown fuse |
Check and replace fuse. | |
| Stepper motor stops working | Stepper driver failure |
Replace stepper driver. |
Power supply failure |
Check power and replace if no power to electronics. For example, it is possible for the 12v power to fail making motors and heaters inoperable. | |
Broken wire |
Check all wiring for stress fractures and loose connectors. Replace as needed. | |
Blown fuse |
Check and replace fuse. | |
Stepper motor overheats |
Wrong voltage on stepper driver |
Measure voltage and set it to match stepper motor. |
| Extruder gears turn but filament pauses before it extrudes | Worn or damaged gears |
Check gears for damage and replace. |
Rounded-out nut trap |
Check large gear for rounded-out nut trap and replace gear. | |
Loose hobbed bolt |
Tighten hobbed bolt. | |
| Extruder stepper motor turns but no filament extrudes | Loose gears |
Tighten or replace gears. |
Extruder jammed |
Check Table A-1 and repair extruder jam. | |
| Squeaks, creaks, scratching, or clunking sounds when axes move | Insufficient lubrication |
Perform regular maintenance to clean and lubricate axis movement. |
Loose axis mechanism |
Check, replace, and tighten axis mechanism. | |
| Axis does not stop at endstop | Broken switch |
Replace endstop. |
Broken or disconnected wire |
Check and replace as needed. | |
Burning smell from electronics |
Short or electronics failure |
Turn computer off immediately. Check electronics for damage. Remove 12v power and connect USB cable to check low-voltage operation. Replace all damaged components. |
Sparks, clicking, or smoke from electronics |
Short or electronics failure |
Turn computer off immediately. Check electronics for damage. Remove 12v power and connect USB cable to check low-voltage operation. Replace all damaged components. |
No lights or LCD display |
Power supply failure |
Replace power supply. |
Unexplained noises when axes move—not related to axis mechanism |
Loose frame components |
Check all frame components and tighten as needed. |
Axis runs into max stop |
Improper homing |
Make sure you home all axis before printing. |
Metal screech from Z-axis rods |
Insufficient lubrication |
Ensure threaded rods are lubricated with the proper lubrication. (e.g., PTFE grease). Check your manual for the correct type to use. |
| Printer vibrates excessively so that it moves across table | Loose frame components |
Check all frame components and tighten as needed. |
Acceleration too high |
Check acceleration settings in firmware. Reduce by 10%. | |
Print speed too high |
Lower infill print speed. |