How to fix odd layers in the middle of a solid
Greetings!
I am looking for some guidance. I am attempting to print some tokens for my friend's bar. This seems like it should be very simple, but I am running into an issue that is causing the prints to take a lot of extra time, and also it seems to "smush" some of the layers causing some of the parts to look terrible and get tossed.
This token consists of a 2.6mm thick, 45mm diameter cylinder that I created using prusa slicer. On top of that, I have placed an .STL of some artwork that was provided by the bar owner. I am printing these with 100% infill and ironing on top surfaces.
The odd thing that happens- About halfway through the solid cylinder, it wants to print a 'ghost' image of the STL that's on top of the cylinder. Then it goes back to solid layers again. If I delete the STL, it's gone. It makes absolutely no sense to me. Any thoughts or suggestions? Thank you.
RE: How to fix odd layers in the middle of a solid
Please, save your project as a *.3mf file, then compress that file with winzip and load the resulting *.zip file here. This way we'll be able to diagnose the possible issues.
RE:
While you are zipping up the .3fm file, you also might ensure you have joined the two objects in Slicer (merge the disk and logo parts into a union).
https://forum.prusa3d.com/forum/prusaslicer/merging-2-stl-objects-into-one-print/
To your question why is this happening, without the 3mf, my only guess is the logo stl is more complex than it seems.
RE: How to fix odd layers in the middle of a solid
Here's the file, thank you for taking a look.
RE: How to fix odd layers in the middle of a solid
That ghosting is one for the guys over at Github. I certainly don't understand what's happening with the slice, and it is easily repeatable using a plain cylinder and PETG logo. It seems to me to be a bug, but a more or less harmless one - just a bit more time printing that layer. I'm not sure they'll do anything with it, but I'd report it just in case.
Be sure to explain why it's a problem for you, production time costs, etc.
RE:
As for the "smushing" -- post a photo of what you're seeing. At first glance I'd probably expect some issues with stringing during the ironing phase; I think it is designed for a simpler flat surface, not the two layers with fine details on top. You might try adding a modifier to apply the ironing to the main cylinder surface and avoid ironing the tree surface.
ps: I did see your tree sits at 2.95mm, and probably should be 2.90mm.
RE: How to fix odd layers in the middle of a solid
Thank you for the reply. I like your idea of only ironing the top of the cylinder, I hadn't thought about that.
The "smushing" issue seems to happen during printing of the odd middle tree layer. In fact it seems to over-extrude it so much that it winds up knocking a small % of the tokens off the bed. It almost seems like it's trying to iron that surface as well even though I have "top" selected for ironing. I will have another look at it tonight.
RE: How to fix odd layers in the middle of a solid
I wonder if the odd layer has anything to do with the text ... you might try slicing with the text layers off and see if the middle messed up layers go away. My logic for this is thinking the text will have a "top layer" that could be confusing things. All the more reason to use a modifier to enable ironing for only that layer range you actually want ironing, if I recall correctly 2.8 to 3.0 mm ...