Learning Hub - Troubleshooting

Troubleshooting Print Failures

Fix Warping, Adhesion & Quality Issues

Diagnose and solve common 3D printing problems, especially for the demanding geometries of automotive parts.

First: Run This Checklist

Before diving into specific issues, verify these basics. Most problems stem from these fundamentals.

Is filament dry?
Moisture causes bubbles, weak layers, stringing. Dry at material-specific temp for 4+ hours.
Is bed properly leveled?
Uneven first layer causes adhesion issues, warping, dimensional problems.
Is nozzle clean and correct size?
Partial clogs cause under-extrusion. Worn nozzles affect precision.
Are belts tight?
Loose belts cause dimensional inaccuracy, ghosting, layer shifts.
Is temperature correct for material?
Too low = weak layers. Too high = stringing, oozing.
Is print speed appropriate?
Too fast causes quality issues. Start at 50mm/s for troubleshooting.
Is cooling appropriate?
Too much = warping, poor adhesion. Too little = droopy overhangs.
Is environment stable?
Drafts cause warping. Temperature swings affect quality.

Warping & Lifting

Common Causes

  • Bed not level

  • Bed temp too low

  • Part cooling too aggressive

  • No enclosure for ABS/ASA

Fixes

  • Level bed with paper test

  • Increase bed temp 5-10°C

  • Reduce fan for first 5 layers

  • Add brim or raft

Common Causes

  • Internal stress from rapid cooling

  • Material shrinkage

  • Thin walls cooling unevenly

Fixes

  • Reduce print speed

  • Use enclosure

  • Increase wall count

  • Anneal part after printing

Common Causes

  • Differential cooling across surface

  • Bed adhesion releasing unevenly

Fixes

  • Print on textured PEI

  • Add mouse ears to corners

  • Use concentric bottom pattern

  • Reduce bed temp gradually at end

Layer Adhesion

Common Causes

  • Nozzle temp too low

  • Print speed too fast

  • Cooling too aggressive

  • Wet filament

Fixes

  • Increase nozzle temp 5-10°C

  • Slow down to 40-50mm/s

  • Reduce cooling fan

  • Dry filament 4-6 hours

Common Causes

  • Under-extrusion

  • Z-offset too high

  • Partial clog

Fixes

  • Increase flow rate 2-5%

  • Lower Z-offset

  • Cold pull to clear nozzle

  • Check for heat creep

Common Causes

  • Wrong print orientation

  • Material too brittle

  • Insufficient walls

Fixes

  • Rotate part for load direction

  • Use PETG/Nylon instead of PLA

  • Increase wall count to 4+

Stringing & Blobs

Common Causes

  • Retraction too short/slow

  • Nozzle temp too high

  • Travel speed too slow

Fixes

  • Increase retraction 1-2mm

  • Reduce temp 5-10°C

  • Increase travel speed to 150mm/s+

Common Causes

  • Over-extrusion

  • Seam placement

  • Coasting/wipe settings wrong

Fixes

  • Reduce flow 2-5%

  • Set seam to "sharpest corner"

  • Enable coasting 0.2-0.4mm

Common Causes

  • Retraction at layer change

  • Z-seam visible

  • Pressure buildup

Fixes

  • Enable "retract at layer change"

  • Hide seam in corner

  • Use linear advance/pressure advance

Dimensional Accuracy

Common Causes

  • Plastic shrinkage

  • Over-extrusion on curves

  • Elephant foot

Fixes

  • Design holes 0.2-0.4mm larger

  • Enable "hole horizontal expansion"

  • Calibrate flow rate

Common Causes

  • Steps/mm miscalibrated

  • Material shrinkage

  • Slicer scaling error

Fixes

  • Calibrate steps/mm with test cube

  • Use horizontal expansion compensation

  • Check slicer units (mm not inches)

Common Causes

  • First layer squished too much

  • Bed temp too high

  • First layer flow too high

Fixes

  • Raise Z-offset slightly

  • Reduce bed temp 5°C

  • Use "elephant foot compensation" 0.1-0.2mm

Surface Quality

Common Causes

  • Overhang angle too steep

  • Cooling insufficient

  • Print speed too fast

Fixes

  • Add supports over 45°

  • Increase cooling to 100%

  • Slow down for overhangs

Common Causes

  • Layer height too tall

  • Inconsistent extrusion

  • Vibration/wobble

Fixes

  • Reduce layer height

  • Calibrate e-steps and flow

  • Tighten belts, check frame

Common Causes

  • Print speed too fast

  • Acceleration too high

  • Loose belts

Fixes

  • Reduce speed and acceleration

  • Enable input shaping if available

  • Tighten belts

Automotive-Specific Issues

Car parts face unique challenges: heat, UV, vibration, and complex geometries.

Large bracket warps overnight
Big flat mounting brackets for bumpers, splitters

Fix: Print with brim, use enclosure even for PETG. Consider splitting into sections and bonding. Anneal after printing.

Clip breaks on install
Snap-fit clips for interior trim

Fix: Wrong material (use PETG/Nylon, not PLA). Wrong orientation (layers parallel to flex). Add fillet at base.

Vent louvers delaminate
AC vents, grille inserts with thin fins

Fix: Print fins vertically if possible. Increase temp for better layer adhesion. Use PETG for flexibility.

Cup holder cracks in summer heat
Interior parts exposed to sun

Fix: PLA glass transition is 60°C - car interiors exceed this. Use PETG (80°C) or ASA (100°C) minimum.

Under-hood part softens/fails
Engine bay brackets, covers

Fix: Need 100°C+ heat resistance. Use ASA, ABS, or Nylon. Glass-filled variants for maximum rigidity.

Exterior trim fades/yellows
Mirror caps, badges, exterior accents

Fix: UV exposure degrades most plastics. Use ASA for UV resistance. Clear coat all exterior parts.

Material-Specific Troubleshooting

PLA (Not Recommended)
Common issues: Softens at 55-60°C, Will warp in car interiors, Brittle, snaps easily

Don't use PLA for car parts. Switch to PETG for easy printing with better heat resistance.

PETG
Common issues: Stringing, Bed adhesion too strong, Moisture absorption

Higher retraction, use glue stick on PEI, dry filament before printing

ABS
Common issues: Warping/cracking, Layer splitting, Fumes

Enclosure required, higher bed temp (100-110°C), ventilation

ASA
Common issues: Similar to ABS, Slightly less warping

Enclosure helps, bed temp 90-100°C, less sensitive than ABS

Nylon
Common issues: Extreme warping, Moisture sensitivity, Bed adhesion

Must be bone dry, use Garolite or glue, enclosed chamber 40-50°C

TPU
Common issues: Stringing, Slow print, Jamming in Bowden

Direct drive preferred, very slow retraction (20mm/s), no retraction for soft TPU

Frequently Asked Questions

Likely heat creep - the heat zone is climbing up the filament path. Check your hotend cooling fan is working. Consider an all-metal hotend if printing high-temp materials.

Layer adhesion issue. Increase print temp, slow down, reduce cooling. Check if filament is wet - moisture dramatically weakens layer bonds.

When printing multiple parts, travel moves can cause oozing that affects dimensions. Print critical mating parts together, or dial in retraction settings.

Environmental factors. Humidity affects filament (dry it). Ambient temperature affects warping. First layer calibration may drift. Create a pre-print checklist.

Still Stuck?

Check your print settings against our recommended profiles, or explore material guides for optimal parameters.

Print Settings GuideMaterials Guide