The 3D printing has revolutionised the way we design, prototype and manufacture products. But it's also true that it's not a plug & play process. Whether you're just starting out or you've already tried printing with suppliers or in-house printers, you've probably encountered some of the following 3D printing problemsThe following are some of the most common problems: pieces that do not stick to the base, misplaced layers, mistakes with the material or unprofessional finishes.
At Additium 3D we hear about these cases every week. That's why we have prepared this error guide y common problems in 3D printing, with practical solutions and real examples. We also tell you how our personalised service helps you avoid these pitfalls from minute one.
Common problems in 3D printing: the most common mistakes and how to fix them
We have compiled a list of the most common faults reported by our customers. Some are technical, others are design-related, others are process-related. All of them can be solved with the right methodology.
1. Problems in the first 3D printing layer
One of the printing errors most frustrating: the first layer does not adhere well to the base, peels off or becomes uneven. This failure is the source of many failed parts.
Possible causes:
- Poorly levelled base
- Incorrect nozzle height
- Incorrectly set speed or temperature
- Dirt on the print bed
How we solve it:
Before printing, we always carry out a professional tuning and we calibrate the appropriate parameters according to the material and geometry. In addition, if your design is not optimised for good adhesion, we adapt it.
2. 3D design errors that prevent correct printing
Many of the 3D printing problems are not in the machine... but in the archive. Models with too thin walls, open geometries, poorly defined supports or without tolerances.
Typical errors:
- Design not suitable for FDM or resin printing
- STL files with mesh errors
- Lack of assembly tolerances
- Thicknesses that compromise strength
Our approach:
We include technical advice and file review before printing. If required, we redesign or correct models to ensure that the print will be workable and functional.
3. Printing errors with PLA (and other materials)
The PLA is one of the most widely used materials, but it is not without its problems. Many errors come from incorrect configuration or misuse of the material.
Most common PLA 3D printing errors:
- Deformations (warping)
- Clogging due to overheating
- Weak layers or poor adhesion
- Extrusion flow problems
What we do differently:
At Additium we use high quality materials, with parameters tested and calibrated on our own printers. We also work with PETG, ABS, Nylon, PA12, technical resins... and we help you to choose the most suitable for your application.
4. Problems when changing filament in 3D printing
The change of filament is another common source of errors: clogging, clogged nozzle, mixing of colours/materials, poor adhesion right after the change.
Additium Solutions:
- Clean and accurate switching protocols
- Purge and flow check
- Test print after every material change
This is key especially in multi-unit productions, where a small mistake can ruin a whole series.
5. Ghosting in 3D printing: wavy or vibrating surfaces
The ghosting or ringing appears when the printer vibrates during fast movements, and an echo effect is generated on the surfaces.
How we avoid it:
- We adjust speed and acceleration for each project
- We optimise the design to avoid abrupt changes in direction.
- We print on professional equipment with stable and calibrated structures.
6. 3D printer flow problems
A incorrect flow The material (over/under extrusion) leads to poorly bonded layers, threads, bubbles or even structural failures.
Our method:
We verify the actual extrusion flow and apply compensations if necessary. In addition, in critical cases we use measurement and simulation techniques to ensure consistency throughout the part.
7. Errors 3D printing with resin
Resin printing (SLA/DLP) has its own particularities. It is common to see curing errors, poor adhesion o incorrectly positioned brackets.
Solutions from Additium:
- Correct orientation of the part
- Strategic placement of supports
- Professional post-curing with controlled UV light
- Cleaning and sanding finishes that remove debris or marks
And now the 3 most common flaws and mistakes in 3D printing and how to fix them effectively
Warping (or how your parts come off the bed and get deformed)
What is warping?
The warping is one of the most common and frustrating defects in 3D printing. It occurs when the edges of a printed part start to lift off the bed, causing the base to curve upwards. This not only ruins the visual finish of the part, but can affect its functionality if the final dimensions change.
Why does this happen?
The main cause is the shrinkage of the plastic as it cools. This effect is more pronounced in materials such as ABS or Nylon, which shrink significantly as they go from molten to solid. If the base of the part cools too quickly, it shrinks more than the top layers, causing internal stress that eventually detaches it from the bed.
Other aggravating factors:
- Poor adhesion to the printing base.
- Poor bed levelling.
- Air currents in the printing environment.
- Use of materials without a hot bed or enclosure.
How can this be avoided?
- Improves adhesion: Use specific lacquers (such as 3Dlac), painter's tape, glue stick or even homemade solutions such as the slurry (ABS + acetone mixture).
- Controls the temperature: Use a heated bed (about 90-110°C for ABS), and if possible, print inside an enclosure to maintain a constant temperature.
- Adjust the first layer: Make sure the nozzle is at the right height. If the nozzle is too high, the filament will not be flattened properly and will peel off easily.
- Avoid draughts: Printing near open windows or fans can lead to temperature differences that can cause warping. Closing the environment or creating an enclosure with cardboard boxes may be sufficient for open printers.
cracking or delamination (when layers separate)
What is Cracking?
The cracking o delamination occurs when the layers of a part are not properly bonded together. To the naked eye, you will notice horizontal cracks or separation lines between layers. This problem is especially common on tall parts or parts with thin geometries.
Why does this happen?
There are two main culprits:
- Lack of temperature: If the extruder is not hot enough, the filament does not melt well and does not adhere to the previous layer.
- Thermal shrinkage between layers: Same as warping, but vertically. If the lower layers are hot and the upper layers cool quickly, stresses are created that can cause the part to «crack» vertically.
How can this be avoided?
- Raise the extruder temperature within the recommended range of the material (especially if you work with ABS).
- Reduces the layer fan or even turn it off when printing on materials that do not require it. Too rapid cooling impairs adhesion.
- Lock up your printer or print in a warm environment. Covering the printer helps the part to maintain an even temperature at all times.
- Avoid printing tall parts with ABS if you have no enclosure. It is better to use materials such as PLA or PETG for vertical parts without a thermal enclosure.
Layer shift or shifted layers (when your part looks like it has been pushed)
What is Layer shift?
The layer shift occurs when the layers are misaligned horizontally. The part starts out fine, but at a certain point it looks like everything has shifted to one side, as if someone has pushed it while printing.
Why is this happening?
- Overheating of motors or drivers: if the electronic components are too hot, the motors may lose steps.
- Mechanical problems: loose belts, poorly fastened parts, dirty or clogged shafts.
- Incorrect configuration of electronics: too low a voltage on the drivers can cause the motors to have insufficient power to move properly.
How to solve it?
- Secure the straps: Neither too tight nor too loose. If they are too loose, the layers will easily come undone.
- Check the axles: Clean and lubricate them. A simple filament residue can cause a small jam.
- Add ventilation: Place heatsinks or fans over the drivers. If the motors make a “knock-knock” sound while printing, this is a sign of overheating.
- Adjusts the voltage of the drivers: Only if you know what you are doing. Consult your motherboard manual and use appropriate tools to avoid damage.
Troubleshooting in 3D printing: what we do at Additium 3D
Instead of simply printing a file, at Additium 3D we offer a comprehensive service How do we do this?
- Technical consultancy
We review the design, analyse its functionality and propose improvements if necessary.
- Advice on materials
We select the most suitable material according to use, resistance, aesthetics and budget.
- Professional printing technology
Industrial FDM, resin, composites... with customised calibration and configuration.
- Finishing and post-processing
Sanding, painting, assembly, polishing... So that the result is functional and visually professional.
- Adapted production and logistics
From single prototypes to medium series. Delivery on tight deadlines, with monitoring at every stage.
Are you having problems with 3D printing?
We know what it's like to fail piece after piece. Or to receive a «supposedly valid» file that doesn't work. Or not knowing what to do when the material does not give the expected result.
That's why at Additium3D we don't just print. You can visit we accompany, advise and manufacture with you, from the first test to the final product.
Whether you are validating an MVP, need technical parts for an industrial product or want to outsource a production, tell us about your case.
- First layer problems in 3D printing?
- Errors with PLA or resin?
- Hosting or flow problems?
We are here to help you. And to make sure that this time, the printing goes well.
