Hey Greg, thanks for the thoughts.
As a spit balling attempt to rectify what we both feel could be a moisture issue, I'm going to heat the filament for a couple of hours prior to use, I'm going to preheat the chamber, I'm going to up the heat of the hottend after the first couple of layers as well as I'll increase the flow hoping to force the two layers together. Oh, and maybe slow it down at that point? Heck, I might even stand over the printer and lower the hottend a few thou while it is in this third layer. :-)
As an FYI, supposedly PP is not bothered by moisture but moist air can rest on the filament. Anyway, I still "dry it" when I get it, I store it in a constant 18% humidity bin, and just prior to using it I "toast" it again. All of which means squat other than I'm trying.
IF I get this sorted, I'll come back and let you know. Shall we leave this open for a short while in case someone else has an idea?
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GregValiant 1,342
Is it possible the filament has picked up moisture? Steam pockets can form and push a layer up. That third layer is the first one that "seals" the gaps that are in the first two layers. I've seen that happen when gaps in infill get sealed off (looks like a bunch of land mines went off) so it's possible that the same sort of thing is happening with your raft.
This is just to show how much denser layer 3 is than 1 and 2.
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