Wall not filling as a solid  

RE: Wall not filling as a solid

Everything is going to be wild guesses without more data. If you upload your project as a 3mf file, you're likely to get better advice, In Prusaslicer, go to File/Save project as, to create the 3mf file. Zip compress it (right click Compress on Mac and WIn11, right click Send to/Compress on Win 10) to turn it into a .zip file, which you can attach to a post on this forum. The forum software does not accept 3mf files, it has to be a zip file.

RE: Wall not filling as a solid

So, here’s my theory: Your printer is extruding the layers with a certain width. Let’s say 1mm wide. With that you can print a wall of exactly 1 mm thick, or a wall of 2mm or more. So, a thickness between 1.5 and 2 mm is not possible! This is because the printer prints the outsides first (1mm wall= 1 line, 2mm wall= 2 lines). If you make a wall 1.5 mm thick it will beme only 1 mm thick or become 2 mm thick. If you define it as 2.5 mm thick, it will not have infill.  Rule of thumb: a truly solid  wall should always have a thickness equal to a multiple of your extrusion width.

so what I think happened with you is that your ‘hollow’ wall has a thickness that not close to a multiple of line width. For instance 2.5 line widths. The printer then prints the outside edges and having only 0.5 mm space between them cannot fill it In. And you’re left with a hollow wall even though you defined it as solid. I think the thinner and thicker walls in your picture have thicknesses that are much closer to a multiple of your extrusion width and are therefore printed solid.

Possible solutions: adjust your extrusion width for the wall thickness or redesign your walls to be a multiple of your extrusion width.

Hope this helps! Good luck.

RE: Wall not filling as a solid

a truly solid  wall should always have a thickness equal to a multiple of your extrusion width.

... well, not exactly. Filament is not being laid down with a rectangular cross section but with a squished ellipse cross section. Adjacent filament extrusions will slightly overlap. So two perimeters of 0.45 mm will not yield 0.9 mm but 0.86mm. For more detail see https://help.prusa3d.com/en/article/layers-and-perimeters_1748/

RE: Wall not filling as a solid

Thanks. I didn’t go into that detail because I thought it would make it more confusing. But you are of course correct.