Missing Infill Layers

[mrjohnk 0]

I troubleshooting an issue regarding the toolpath generated does not call for infill on two layers in the middle of my model, but it does do a perimeter run on each. After two layers of no infill, then the next infill comes along and kinda droops and sags as it is printing in a relative void and it doesn't' really attach well to anything. I tried to use Netfabb to repair the part, if anything was wrong with it, but no help. I have attached the STL model file and the Cura profile I'm using. It is layers 16, 17 & 18 that I'm concerned with. The first two do an outline, then layer 18 start the infill again. Once the parts are off the printer, several of them separate easily at this point while I'm trimming them up, however, they are supposed to be solid. Any thoughts on the best way to keep this from happening?

A little background on the part: It is a button. Essentially a cube attached to a cylinder. I have added support structures around the edge to hold up the larger cube that is sitting on top of the smaller cylinder. These support are meant to be break-away, so they barely intersect into the model. It is at this intersection point of the supports where the infill layers are not present.

Yes, some of the settings in the profile are kinda wonky like using a nozzle size of 0.5, overlap of 65% and filament size of 3.2mm. These are to control some of the fine detail and keep from over-extruding. Each tiny button is "engraved" with a number so getting fine detail is challenging and these seem to help. As far as I can tell, these setting are doing their intended job of getting the engraved portion done, but not causing lack of infill issue I'm having with the middle of the model.

Thanks for any help.

-John

[Daid 301]

An infill overlap of more then 45% is known to cause problems, and ridiculous.

[mrjohnk 0]

After seeing the warning, I did back the overlap back down to 12% to see if that fixes it, but I didn't have any luck correcting the issue with that.