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La correcta adhesión entre la pieza y la base es fundamental para evitar fallos durante la impresión. La unión entre la primera capa de impresión y la superficie de la plataforma cumple dos funciones básicas:
The adhesion between the part and the base is mainly determined by four factors.
The physico-chemical affinity between the printing material and the substrate surface is perhaps the most important parameter to take into account. This is why nowadays it is common to use polymeric coatings specifically developed for 3D printing on the surface of the platform. It is very important to use a product that is compatible with the printing material used, as some materials, such as PP or nylon, require specific products. There are mainly two types of solutions:
A larger contact surface between the part and the base produces greater adhesion. Care must be taken with large parts in printers without a heated chamber, as despite having a larger contact surface, their volume is also greater and therefore the stresses derived from cooling shrinkage. The most commonly used resource to increase the contact surface is to set an edge to the part during lamination. The edge shall be applied only on the first layer or in some cases on the first 2 or 3 layers, increasing the contact surface of the part without increasing the shrinkage stresses. There are other ways to increase the contact surface, such as increasing the extrusion factor during the first layer, although this is not recommended.
Some printers also include rough or textured coatings, which is another way to increase the contact surface and therefore adhesion.
The temperature of the printing base has a double function in terms of adhesion. On the one hand, if it is equal to or slightly higher than the Tg of the printing material, it will prevent shrinkage due to cooling of the first layers, reducing the stresses that tend to lift or peel off the part. On the other hand, it favours the chemical bonding between the printing material and the coating material of the printing surface. It is recommended that the temperature of the base is equal to or slightly higher than the Tg of the printing material, however it is not advisable to set much higher temperatures, as they can reduce adhesion and cause deformations such as elephant foot.
It is also very important to check the condition of our printing base. In spite of complying with the three previous points, there may still be adhesion problems due to poor condition or maintenance of the base. The following points should be checked periodically:
The main consequence of poor adhesion to the printing surface is that the part detaches from the base. This will always result in print failure, however, in some cases, it can also be the cause of equipment failure or breakage.If the part detaches and moves away from its original position, the printer will continue to print without having a substrate on which to deposit the new material. This will cause the plastic to stick to the nozzle and block, forming a mass that will grow as the printing progresses. If not stopped in time, this mass of molten plastic will grow so large that it can render the hotend unusable.
In order to understand and solve adhesion problems, it must be taken into account that the part can be detached by two mechanisms.
If there is no good adhesion between the printing surface and the first layer, the part will peel off completely due to the friction of the nozzle during printing and vibrations. Generally the failure will occur at the beginning of the printing process. In this case it is advisable to check the following points:
It may be that there is a very good adhesion to the base, but the part starts to peel off at the ends. This is because the shrinkage during cooling generates stresses from the outside of the part towards the centre that cause it to deform. In these cases, the adhesion between the part and the base is not sufficient to compensate for the stresses generated by the shrinkage. This phenomenon is known as warping. In this case, the part progressively peels off and the print can fail at any time, even a few minutes before completion.In this case, attempts can be made to improve adhesion to compensate for warping, but other factors such as lamination parameters, material type or ambient temperature must be considered.
In some cases, excessive adhesion to the base can make it really difficult to separate the part. In these cases the following should be checked:
When a problem of excessive adhesion appears, there are several ways to encourage the removal of the parts:
When using glass bases it is necessary to be particularly careful, as there is a high risk of breakage. It is not uncommon for a fragment of the surface of a tempered glass base to be torn off when removing pieces that are too tightly glued together.
The use of flexible bases avoids this problem to a large extent and is therefore a highly recommended option.
This guide discusses concepts in a general way and does not focus on a particular make or model, although they may be mentioned at some point. There may be important differences in calibration or adjustment procedures between different makes and models, so it is recommended that the manufacturer's manual be consulted before reading this guide.
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