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Gears merge during slicing  

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NickB
(@nickb)
Member
Gears merge during slicing

https://photos.app.goo.gl/E7PwckvbwMrXLHox5

I am trying to prevent the gears from merging in Prusa Slicer, it has printed well in the past, but is merging once sliced. I have confirmed no interference in  Fusion 360. Thanks!

Posted : 15/08/2025 12:28 pm
UjinDesign
(@ujindesign)
Estimable Member
RE: Gears merge during slicing

Hey, Neophil answered the same question I posed over here  https://forum.prusa3d.com/forum/prusaslicer/prusa-slicer-merging-my-print-in-place-bodies/

Posted : 15/08/2025 3:21 pm
NickB
(@nickb)
Member
Topic starter answered:
RE: Gears merge during slicing

Thank you! I thought I tried that setting, but will have to double check. I appreciate the link.

Posted : 16/08/2025 2:33 am
NickB
(@nickb)
Member
Topic starter answered:
RE: Gears merge during slicing

After adjusting the Slice gap closing radius to 0, the same thing is occuring. I have successfully sliced and printed this object a few times, but modified the exterior radius and each time I slice it the gears are merged with the body in the same way. I have printed successfully with lowered extruder multiplier (0.95), but lately that has not been working.

Posted : 16/08/2025 2:40 am
Neophyl
(@neophyl)
Illustrious Member
RE: Gears merge during slicing

Yeah this comes up all the time.  Theres multiple posts in this forum about it but the forum search here sucks 🙂  Wordpress for you.

Over on the prusa slicer github there's also multiple ones (mostly closed now to remove duplicates) but you can read more about it on this one https://github.com/prusa3d/PrusaSlicer/issues/8460  

From your last post does the sliced file have the gap or not ?  If the sliced output has a gap but your printed model doesn't then that's obviously a different issue.

Posted : 16/08/2025 1:49 pm
1 people liked
NickB
(@nickb)
Member
Topic starter answered:
RE: Gears merge during slicing

Adjusting the slice gap closing radius did not solve the problem. It appears the STL which I am importing has a small intersection looking at the unsliced object on the plater. I will have to see if I can modify the Fusion file. I'm basing this on a thingiverse model, and remixing to fit additional coffee portafilters.

https://www.thingiverse.com/thing:5398558

Posted : 16/08/2025 8:17 pm
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