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Theory on Warping

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Posted · Theory on Warping

I have a theory that thinner layers and thinner extrusion leads to more warping.  The basic thought I have in my head is that if you're printing thin layers, near or below the nozzle width, then you're smearing and stretching the filament, leading to higher stress and potential warping.


It's easy enough to find a print that's prone to warping, print with different settings and then eyeball the result.  But I'm wondering if anyone has taken a truly scientific approach with this and has good numbers?  Maybe even measured stress with some fancy hardware?


What do you think?  Agree or disagree?  Did I miss something obvious or something counter-intuitive?  Know of any existing hard data?

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    Posted · Theory on Warping

    Warping-tendency on the bed *while printing* seems to be lower with thinner layers: their bottom is flatter and has a bigger contact-area to the bed than thicker layers, so a better adhesion and less warping. Also, a very thin layer can excert less forces while cooling than a thick layer. A 0.3mm layer suddenly cooling down and shrinking will be able to pull much harder than a 0.06mm layer, I think.


    But for warping afterwards, for example the completed part sitting in the sun or in weather, I have no idea. Prints with thicker layers have more entrapped air (=are less transparent) than prints with thin layers. But I don't know if and how that would affect internal stresses and warping afterwards? Interesting thought though.

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