Bulge remedied but still exists as an overall wider upper wall?  

RE: Bulge remedied but still exists as an overall wider upper wall?

Have you calibrated your extrusion multiplier for that filament? Other than that, your 3rd pic from the bottom may be as good as it gets. Can you actually feel the defect there? Lighting and filament make a big difference in visual appearance. 

If you want to zip up the 3MF project file and attach it here, we can take a look at it. IME, those defects occur when there's a transition of the wall infill from sparse infill to either sparse infill or gap fill. Making the walls a bit thicker might help if that's a possibility. Otherwise, tweaking extrusion widths may be as good as it gets with PrusaSlicer.

Someday I plan to spend more time on this and open an issue on github.

RE: Bulge remedied but still exists as an overall wider upper wall?

Hey Bobstro!

Thanks for replying.  I use your intro/purge line and love it.  Helps my prints be more successful for sure!

I can both feel and see that ledge.  It's very subtle compared to what it was before but it's still there.  Looks good to my lesser trained eye in Prusa Slicer.  I have not yet done the extrusion multiplier calibration for this particular filament minus some stare and compare tests from .96 up to 1.0.  I can do the official process tonight after this current print completes and report back.

I've attached my 3mf file here.  Appreciate any input!

RE: Bulge remedied but still exists as an overall wider upper wall?

FWIW, I'm printing the right half of this with default PETG settings minus a few settings like temps, seam on rear, 30% infill, brim width increased and zero elephant foot compensation so my brim is attached.  Will see how this goes...

RE: Bulge remedied but still exists as an overall wider upper wall?

I measured my 40x40x40 vase cube with micrometers in multiple locations and it's .45 so my extrusion mutliplier should be 1.0.

RE: Bulge remedied but still exists as an overall wider upper wall?

Unfortunately I’ve come to accept this as an artifact PrusaSlicer creates in the situation @bobstro defined. Most pronounced in models with internal flat surfaces. In my hands I didn’t see much if any impact of adjusting extrusion multipliers, and while thicker walls help that’s not always possible. 

RE: Bulge remedied but still exists as an overall wider upper wall?

Posted by: @jurassic73

[...] Thanks for replying.  I use your intro/purge line and love it.  Helps my prints be more successful for sure!

Glad it's useful. The PINDA warmup is not strictly required with newer PINDA versions, but I find warming everything up before printing helps consistency, particularly with the seasonal temperature swings.

I can both feel and see that ledge.  It's very subtle compared to what it was before but it's still there.  Looks good to my lesser trained eye in Prusa Slicer.  I have not yet done the extrusion multiplier calibration for this particular filament minus some stare and compare tests from .96 up to 1.0.  I can do the official process tonight after this current print completes and report back.

One thing I always forget to emphasize. The slightest bit of warping is going to contribute to these problems. Inspect the bottom of the print and see if any corners have lifted at all. I find this a problem on larger prints. If so, work on bed adhesion. There are a lot of factors that can lead to chasing one's tail, unfortunately.

I've attached my 3mf file here.  Appreciate any input!

Attachment removed

I've cut off a piece with the sharper curved corner and am doing some test prints. It's still a 1h39m print, unfortunately.

RE: Bulge remedied but still exists as an overall wider upper wall?

Posted by: @jurassic73

[...] I've attached my 3mf file here.  Appreciate any input!

I've cut down the part to just the long edge with the 2 rounded corners. Unfortunately, it's still a 4 hour print.

I noticed in your settings that you're using very conservative settings. You've got 4 perimeters, aligned the seam, print external perimeters first, are using a brim, and are using 15mm/s for most moves. Are you still seeing a pronounced defect with these settings? My print is only halfway done, but looks pretty good so far.

RE: Bulge remedied but still exists as an overall wider upper wall?

Just an FYI that there is another ongoing discussion on this topic that might be worth monitoring.

Here are my results with a cut-down version of @jurassic-73's part. Right-click the image and open in a new tab to see the full image.

1. Printed with Prusa default profiles for 0.4mm nozzle, Prusa PLA, and 0.2mm FAST profile.
2. My profiles with 2 perimeters.
3. My profiles with 4 perimeters.
4. Jurassic's settings as provided in the 3MF file.

These were deliberately photographed highly zoomed-in with harsh lighting to emphasize the defect.

1. The Prusa defaults result in the worst defect. The line is clearly visible as a step outwards as the print moves from sparse infill (the "inside" of the part bottom) to walls. The line can clearly be felt with a fingernail.
2. My normal settings look much better under normal lighting. There is a visible dark-ish line at the transition layer with a single-layer outward bulge, but it cannot be felt with a fingernail. 
3. My settings with the extra perimeters -- essentially just turning the wall into pure perimeters with no sparse infill -- has a softer bulge that seems dissipated over many layers. It's "softer" but still a slight bulge. Again, visible but not readily felt with a fingernail.
4. Jurassic's super-slow settings with brim give the best overall result. The line is visible under harsh light when magnified, but looks near perfect under normal light.

Unfortunately, I think this is going to be an issue that depends entirely on the shape of a specific print, the filament used, and individual user settings. The best I'm able to come up with is the usual "things to try". Definitely make sure you're not having any warping as that will really confuse things and look like the same defect.

I'm doing comparison prints sliced with Cura and ideaMaker for completeness, but here again, different individual settings may come into place. The cut-down print is still a 2 hour print, so it will take a bit of time.

RE: Bulge remedied but still exists as an overall wider upper wall?

Anyone know if the newly released slicer and firmware address this bugle issue?

RE: Bulge remedied but still exists as an overall wider upper wall?

@jurassic73

No, it didn’t. 

RE: Bulge remedied but still exists as an overall wider upper wall?

Posted by: @fuchsr

@jurassic73

No, it didn’t. 

Thanks for the reply.  Maybe next update... 🙂

RE: Bulge remedied but still exists as an overall wider upper wall?

If an object is made up of width and length dimensions that are all divisible by .4, does this make a difference?  Say a box that has 4mm walls and the overall  box width is 40mmx40mm and the floor is 4mm high while printed with a .4mm nozzle?

RE: Bulge remedied but still exists as an overall wider upper wall?

Posted by: @jurassic73

Anyone know if the newly released slicer and firmware address this bugle issue?