Layer to Layer Adhesion/Warping? [ABS/0.05/0.4 Nozzle]
Hello everyone,
I've been trying to push my MK4S to the limits and test some things out of curiosity. My current goal is to consistently get good results at 0.05 layer height with a 0.2 nozzle, and I've run into some issues along the way and I'm currently stuck at 0.05/0.4 Nozzle.
The Issue(s)
It appears that the prints are experiencing warping (possible among other things) and layer-to-layer adhesion issues after the first layer. It looks like some parts/corners are either just warping, getting pulled upwards by the nozzle, or have some messy extrusion(I think this may be the result of a layer separating and warping upwards and then causing a blob). See images here.
There are two additional issues, which are, I think, caused by this:
The first one is bed adhesion: Prints keep getting loose, and I think the issue is, that the nozzle bumps against the warped layers and eventually kick them loose. Currently, bed adhesion isn't an issue anymore, my settings seem to keep the print attached no matter what.
The second one is breaking supports: The organic supports just keep snapping off, leading to issues.
What I've tried
I played around with print speeds, temperature and cooling, but so far nothing conclusive. It took me a lot of trial and error to even get 0.1 working somewhat reliably, so I hope some kind soul spares me another week or two of trial and error by at least pointing me at what settings I should focus on.
The Setup
Printer: MK4S with newest firmware
Slicer: PrusaSlicer (I've considered updating to the release candidate but decided to hold off for now)
Nozzle: 0.4 High Flow
Filament: Prusa ABS
Enclosure: Yes, fully. It keeps the heat well, the fan to pull out fumes is fairly far away from the print.
Layer Height: 0.05
Model: Irrelevant, it happens on all of my test models.
Supports: Organic, everywhere, auto generated (I know this isn't ideal, but I don't want to spend too much time fiddling with painted supports on test prints)
These settings are based on the MK4 Ultra Detail 0.05 settings, but the issue already existed with the standard MK4S 0.1 settings.
No changes to printer settings and filament settings. I did some fiddling with temperature and cooling (235 without cooling vs 255 with cooling) and it didn't seem to make a difference, so I stuck to the standard 255 with cooling. I know that ABS doesn't like air flow, but from a couple of tests it didn't seem to change anything (I'm willing to try again though, with some feedback).
# generated by PrusaSlicer 2.9.0 on 2025-03-07 at 15:16:46 UTC
arc_fitting = emit_center
automatic_extrusion_widths = 0
automatic_infill_combination = 0
automatic_infill_combination_max_layer_height = 100%
avoid_crossing_curled_overhangs = 0
avoid_crossing_perimeters = 0
avoid_crossing_perimeters_max_detour = 0
bottom_fill_pattern = monotonic
bottom_solid_layers = 10
bottom_solid_min_thickness = 0.5
bridge_acceleration = 300
bridge_angle = 0
bridge_flow_ratio = 1
bridge_speed = 25
brim_separation = 0.1
brim_type = outer_only
brim_width = 15
compatible_printers =
compatible_printers_condition = printer_notes=~/.*MK4S.*/ and nozzle_diameter[0]==0.4
complete_objects = 0
default_acceleration = 800
dont_support_bridges = 0
draft_shield = disabled
elefant_foot_compensation = 0.2
enable_dynamic_overhang_speeds = 1
ensure_vertical_shell_thickness = enabled
external_perimeter_acceleration = 300
external_perimeter_extrusion_width = 0.45
external_perimeter_speed = 20
external_perimeters_first = 0
extra_perimeters = 0
extra_perimeters_on_overhangs = 0
extruder_clearance_height = 14
extruder_clearance_radius = 45
extrusion_width = 0.45
fill_angle = 45
fill_density = 15%
fill_pattern = grid
first_layer_acceleration = 500
first_layer_acceleration_over_raft = 0
first_layer_extrusion_width = 0.5
first_layer_height = 0.4
first_layer_speed = 10
first_layer_speed_over_raft = 30
fuzzy_skin = none
fuzzy_skin_point_dist = 0.8
fuzzy_skin_thickness = 0.3
gap_fill_enabled = 1
gap_fill_speed = 25
gcode_comments = 0
gcode_label_objects = firmware
gcode_resolution = 0.008
gcode_substitutions =
infill_acceleration = 800
infill_anchor = 2
infill_anchor_max = 12
infill_every_layers = 1
infill_extruder = 1
infill_extrusion_width = 0.45
infill_first = 0
infill_overlap = 15%
infill_speed = 60
inherits =
interface_shells = 0
ironing = 0
ironing_flowrate = 15%
ironing_spacing = 0.1
ironing_speed = 15
ironing_type = top
layer_height = 0.05
max_print_speed = 100
max_volumetric_extrusion_rate_slope_negative = 0
max_volumetric_extrusion_rate_slope_positive = 0
max_volumetric_speed = 0
min_bead_width = 85%
min_feature_size = 25%
min_skirt_length = 4
mmu_segmented_region_interlocking_depth = 0
mmu_segmented_region_max_width = 0
notes =
only_one_perimeter_first_layer = 0
only_retract_when_crossing_perimeters = 0
ooze_prevention = 0
output_filename_format = {input_filename_base}_0.4n_{layer_height}mm_{printing_filament_types}_{printer_model}_{print_time}.gcode
overhang_speed_0 = 15
overhang_speed_1 = 25
overhang_speed_2 = 30
overhang_speed_3 = 80%
overhangs = 1
perimeter_acceleration = 300
perimeter_extruder = 1
perimeter_extrusion_width = 0.45
perimeter_generator = arachne
perimeter_speed = 30
perimeters = 3
post_process =
print_settings_id =
raft_contact_distance = 0.15
raft_expansion = 1.5
raft_first_layer_density = 80%
raft_first_layer_expansion = 3.5
raft_layers = 0
resolution = 0
scarf_seam_entire_loop = 0
scarf_seam_length = 20
scarf_seam_max_segment_length = 1
scarf_seam_on_inner_perimeters = 0
scarf_seam_only_on_smooth = 1
scarf_seam_placement = nowhere
scarf_seam_start_height = 0%
seam_gap_distance = 15%
seam_position = aligned
single_extruder_multi_material_priming = 0
skirt_distance = 6
skirt_height = 6
skirts = 0
slice_closing_radius = 0.049
slicing_mode = regular
small_perimeter_speed = 20
solid_infill_acceleration = 700
solid_infill_below_area = 0
solid_infill_every_layers = 0
solid_infill_extruder = 1
solid_infill_extrusion_width = 0.45
solid_infill_speed = 60
spiral_vase = 0
staggered_inner_seams = 0
standby_temperature_delta = -5
support_material = 1
support_material_angle = 0
support_material_auto = 1
support_material_bottom_contact_distance = 0
support_material_bottom_interface_layers = 0
support_material_buildplate_only = 0
support_material_closing_radius = 2
support_material_contact_distance = 0.17
support_material_enforce_layers = 0
support_material_extruder = 0
support_material_extrusion_width = 0.4
support_material_interface_contact_loops = 0
support_material_interface_extruder = 0
support_material_interface_layers = 3
support_material_interface_pattern = auto
support_material_interface_spacing = 0.2
support_material_interface_speed = 80%
support_material_pattern = rectilinear
support_material_spacing = 2
support_material_speed = 30
support_material_style = organic
support_material_synchronize_layers = 0
support_material_threshold = 40
support_material_with_sheath = 0
support_material_xy_spacing = 80%
support_tree_angle = 40
support_tree_angle_slow = 25
support_tree_branch_diameter = 2
support_tree_branch_diameter_angle = 5
support_tree_branch_diameter_double_wall = 3
support_tree_branch_distance = 1
support_tree_tip_diameter = 0.8
support_tree_top_rate = 30%
thick_bridges = 1
thin_walls = 0
top_fill_pattern = monotoniclines
top_infill_extrusion_width = 0.4
top_one_perimeter_type = none
top_solid_infill_acceleration = 500
top_solid_infill_speed = 30
top_solid_layers = 14
top_solid_min_thickness = 0.7
travel_acceleration = 4000
travel_speed = 300
travel_speed_z = 12
wall_distribution_count = 1
wall_transition_angle = 10
wall_transition_filter_deviation = 25%
wall_transition_length = 100%
wipe_tower = 1
wipe_tower_acceleration = 0
wipe_tower_bridging = 10
wipe_tower_brim_width = 2
wipe_tower_cone_angle = 25
wipe_tower_extra_flow = 250%
wipe_tower_extra_spacing = 110%
wipe_tower_extruder = 0
wipe_tower_no_sparse_layers = 0
wipe_tower_width = 60
xy_size_compensation = 0
RE: Layer to Layer Adhesion/Warping? [ABS/0.05/0.4 Nozzle]
Hi Koraz,
you seem to be using a sledge hammer to do micro surgery.
the High flow nozzle is designed to flow lots of filament
low layer heights need precise control of small amounts of filament
these seem at odds with each other
why don't you start with a 0.25mm nozzle and 0.12mm layer height, and work down from there?
regards Joan
I try to make safe suggestions,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions, what you do, is YOUR responsibility.Location Halifax UK
RE: Layer to Layer Adhesion/Warping? [ABS/0.05/0.4 Nozzle]
Hi Joan,
Thanks for the advice. I swapped to the .25 nozzle and it seems to alleviate the overextrusion a bit (I'm still doing tests), but the issue with breaking organic supports remain. I'm having difficulties determining the reason and if it's layer-to-layer adhesion issues or if the supports just... break. In any case, the fault lines seem to not be perfectly aligned with the layer lines, there's some breaking across multiple layers.
I got curious, so I jumped to 0.05, and right now I'm using just the stock profile. The only idea I have to increase robustness of supports would be to make them thicker, but there doesn't seem to be an option for increasing number of perimeters, and I'm not sure what else I could change.
RE: Layer to Layer Adhesion/Warping? [ABS/0.05/0.4 Nozzle]
I can't seem to edit my previous post, but I did some more testing and managed to catch a print with issues early on. There seems to be some significant shifting and warping on the x/y axis, but only for the supports, and I caught two supports warping/disadhering on Z. It seems like the supports like to unravel and sometimes the printer manages to press them back down and keep printing the support correctly, but this creates a weakness that will eventually break. I don't see any of this on the print piece itself, so maybe it really is down to two perimeters not being enough?
RE: Layer to Layer Adhesion/Warping? [ABS/0.05/0.4 Nozzle]
After doing some more tests and getting the exact same result every time, I got suspicious and decided to examine the gcodes closer. Turns out, this seems to be an issue with support generation:
It seems like PrusaSlicer simply generates broken supports. This is all on stock settings regarding organic support generation. Does anybody know how to fix this, or should I look at a different slicer for organic supports for now?