Max Team XL, Part 3: Why extremely long print times are every 3D printer’s nightmare

When tackling the printing of large and complex parts, like in our Max Team XL project, you encounter challenges that can completely change your perspective on 3D printing. On the one hand, it’s great that once you start the print, you don’t have to do much else – you just wait for the printer to finish its job. On the other hand, this “convenient” approach brings problems that can jeopardise the entire project.

Support settings

One of the issues Jirka faced was minor print errors due to improperly set supports. Jirka said: “Even though I generated my own custom supports, there were times when they failed.” Adding to this were material issues – during printing, the material slightly warped, leading to visible deformations on the surface of the parts.

Testing and fine-tuning

The next step involved testing the front and rear axles of the car. So far, Jirka have printed everything with PLA, which is a great material for most applications. However, to increase durability, he decided that the rear axle would feature a differential made from PC Blend, a material that better withstands stress.

Long print times: Every 3D printer’s nightmare

One of the biggest challenges was the extremely long print times. Some parts took up to three days to print, presenting significant risks. Any change in office temperature had the potential to negatively impact print quality. And that’s exactly what happened. When we cooled the office during the day to make it bearable, the material started to “work” resulting in undesirable deformations on the parts. This issue isn’t due to the 3D printer itself but rather the environment in which the printing occurs. Maintaining a constant temperature throughout the print is crucial for achieving perfect results.

Are we approaching the printing finish line?

Despite the challenges, we continue to print. The long printing times have been problematic, but the end result is worth it. Jirka has documented some of the errors and deformations that occurred during printing .

The key to successful 3D printing

This project has shown that success isn’t just about having a high-quality 3D printer but also careful planning, the right environmental conditions, and material availability. If you’re embarking on a similar project, don’t forget the importance of maintaining a constant temperature and meticulous support preparation. Every step in the process significantly affects the final print quality.

Looking forward to the next steps in this project and the experiences they will bring. 🙂