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What caused one ugly edge in support interface layers?  

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prusanewuser
(@prusanewuser)
Honorable Member
What caused one ugly edge in support interface layers?

Hi, I have been printing similar things for 2+ years without issue but for the past few days, one side of the edge (in support material interface layers) is always printed badly while the other side is always printed nicely. This causes an ugly edge at the overhang layer as well as a few layers above it. The side printed badly (A in the photo) is further away from me. The strange thing is that after rotating the object by 180 degrees, it is also the side further away from me printed badly. In the preview of Prusa Slicer, both sides look fine. What are possible causes?

Top view of the last support interface layer before printing overhang layer:

[img] [/img]

Ugly looking edge:

[img] [/img]

Good looking edge:

[img] [/img]

This topic was modified 2 months ago 5 times by prusanewuser
Posted : 29/11/2022 5:08 pm
prusanewuser
(@prusanewuser)
Honorable Member
Topic starter answered:
RE: What caused one ugly edge in support interface layers?

Forgot to mention I am using Revo 6. No such problem using it to print such things before.

Posted : 29/11/2022 6:39 pm
RandyM9
(@randym9)
Honorable Member
RE: What caused one ugly edge in support interface layers?

Check your print fan and cooling settings. If it’s the far edge it won’t get the same airflow as the near edge.

Can you turn the print 90* instead of 180* to see if that has an effect?

Cheers

Posted : 30/11/2022 4:44 am
prusanewuser
(@prusanewuser)
Honorable Member
Topic starter answered:
RE: What caused one ugly edge in support interface layers?

Thanks. What print fan and cooling settings am I supposed to have? I don't recall having changed those settings.

I will try to print at 90 degrees and see.

Posted : 30/11/2022 3:20 pm
prusanewuser
(@prusanewuser)
Honorable Member
Topic starter answered:
RE:

@randym9 When I posted yesterday, I could see the effect easily. After seeing your post, even I moved the object to the middle of the head bed, I could still see the effect easily. This is strange because when I printed it near the edge of the build plate, only the edge further from me (closer to the edge of the build plate) had this effect. Moving the entire object to the middle of the build plate should have eliminated that effect but it didn't.

Then, I rotated this rectangular shaped object by 90 degrees as you suggested. One of the longer edges still has this effect but the appearance is greatly improved. I had to put it very closely to see it.  Unlike previous tests, the (shorter) edge further from me did not have this effect. 

So, why one of the longer edges had this problem?

This post was modified 2 months ago by prusanewuser
Posted : 30/11/2022 8:06 pm
prusanewuser
(@prusanewuser)
Honorable Member
Topic starter answered:
RE: What caused one ugly edge in support interface layers?

Tried another test. Rotated by 90 degrees in another direction and the result is not as good. Still a bit better than the one in the photos.

Posted : 01/12/2022 12:36 am
RandyM9
(@randym9)
Honorable Member
RE: What caused one ugly edge in support interface layers?

Sorry for the delayed response, just checking in and saw your posts.

By ‘check the print fan’ I mean make sure it’s working and spinning freely. Also make sure there’s no accumulation of debris, dust, filament strands, or other junk in the fan housing reducing the airflow.

By ‘check your cooling settings’ I mean in PrusaSlicer. There are a variety of fan settings you can adjust including thresholds for minimum and maximum speeds. 

It might be helpful if you uploaded the 3mf file of your print so folks here can see what your printing and all of your settings. In PrusaSlicer, save your print as a project file then zip the resulting 3mf file and post it back here. You have to zip it for the forum to allow the upload.

There are many forum members with exceptional print tuning skills that may also take a look and offer useful suggestions.

Cheers

Posted : 01/12/2022 5:23 am
fuchsr
(@fuchsr)
Famed Member
RE: What caused one ugly edge in support interface layers?

Everything points to cooling as the culprit. I have no experience with the Revo but I'm wondering if the part cooling fan is blowing at it the same way it is blowing at the stock hotend. I vaguely remember reading something about it. Or could be a fan gone bad but that's less likely.

Posted : 01/12/2022 10:19 pm
prusanewuser
(@prusanewuser)
Honorable Member
Topic starter answered:
RE: What caused one ugly edge in support interface layers?

Should it be cooler or hotter?

I wonder if it is better to change the cooling system when the Revo 6 is used. Perhaps somebody has a better mod?

Posted : 02/12/2022 10:04 pm
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