Thanks for your reply,
So is there no way to improve this surface between the support material and the outer layer?
I have tried slowing the print speed of the outer layer, also changing the heat of the nozzle so that the plastic is extruded at a lower temperature and less likely to droop, along with changing the overlap of the extrusion.
I thought that some of these may improve the quality of the layer.
Any other thoughts on this?
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There is no easy answer to this. Forks, spoons, knives are particularly challenging. I recommend printing the fork vertical with the tines pointing up. Use lots of brim at the bottom. Lower your XY acceleration from typical of 5000mm/sec/sec to maybe 1000mm/sec/sec to reduce shaking (you can do this after it has been printing for a while - in fact everyone should try this in TUNE menu just to experience the difference - consider lowering JERK from 20 to 5 also). It should work okay vertical. It should stick fine if you use heat and glue and the first layer presses in nicely flat.
Alternatively make some kind of curved mold/jig out of some material that can withstand 100C such as ceramic, wood, glass. Then print the fork flat and when it is done heat it in just-boiled hot water and do the final curvature of the fork on the mold/jig.
Or you can clean up the rough surface on the fork with wet sandpaper. Just put water on regular sand paper. But it's not as good as the other solutions.
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