Rob

Testing the limits with wave overhangs. From the 3rd revolution onward the errors stack up and result in layers failing.

It seems like the 100th sample is a failed one...

Don't know how this one failed so bad. Changing the temperature next sample.

Best TPU print so far. Huge amounts of warping

Very rough TPU print

Really good PETG-CF sample, some minor lifting near the edge of the print but looking really good.

Don't know what exactly happened to this one, might be underextrusion or temperature too low.

Failed TPU print

First PETG-CF print. Looking good but has some lifting near the corner

First TPU test, simply failed

Trying to find the limit of what is possible with this technique. A1 mini knocked the print off the bed because it kept returning to a position for time lapse

Inclined overhang with a corner. Looks great and wave overhangs handle this really well.

Trying different things to remove the lifting in the corner

Slight lifting in edge

Tried to see how PLA would handle the same inclined part. The first layer where the overhanging section becomes bigger failed

Even better than last PLA-GF sample, slight lifting near edge

Tried to make an inclined and thicker overhanging version of the test prints, only one layer makes use of wave propagation

Connection with the base support is better than last slicer version, slight lifting near the edge

Tried replicating the best PETG result with the new slicer version, looks great

Tried replicating the same result on a different printer. More warping observed.

Lot of warping and rough surface finishes.

Tried using only the auxiliary fan for cooling on the overhanging section per request. Very straight overhang, only when the pattern is automatically switched to monotonic does it fail. Intralayer thermal gradient seems to be minimized.

Only a slight disconnection between the waves and top layer causing a weakness. This issue is known and will be worked on.

Only minimal warping of the PETG. Set the minimum wave time to 4 seconds to ensure that the sharp corners are filled.

Again almost there, the minimum wave time is just slightly too much as the outer edge starts drooping a bit, changing it to 4 seconds next sample.

Looking good, weird texture on the bottom side and slight warping.

Good layer adhesion, weird texture on both top and bottom surfaces. Slight warping

Monotonic pattern caused print to fail.

Slight disconnection between the base of the model and the overhang. Looking good already but needs tweaking.

Almost perfect again, slight lifting again, trying a different wave pattern next sample.

First successful PLA-GF print, line spacing needs to be smaller to make layers adhere well. Needs more tweaking for more successful print.

Almost perfect, just a small amount of lifting filament in the corner.

Line spacing too high, line do not adhere well. Also the black ABS is mixed into the base.

Good PETG print, filament lifting near the smaller waves.

Looks good, only issue is warping. Probably the best ABS will get.

Small amount of warping, nearly perfect.

More warping than last ABS sample, might be caused by me opening the enclosure during the wave section.

Low amount of warping, small amount of lifting near the smaller wave section.

Slightly better than last ABS print. Least warping so far.

Line spacing a tad bit too much. Layers are seperating. Only slight warping. Ends of the smaller waves stick out again.

Slight warping, noticed some curling on individual layers near the smaller waves.

Good adhesion, some gaps between the waves and perimeter. Slight warping

Very good adhesion between layers. Slight warping, not quite perfect.

Good result, only there is a lot of warping present.

Line spacing increased too much. Interlayer adhesion is suffering.

Looking really good, still a lot of warping.

Huge step back from the last ABS print. Looks like underextrusion, will try higher wave flow next.

Only problem with this print is the amount of warping observed.

Better than the other PHA samples, but still not good enough. PHA warps in a completely different way than the other materials, PHA might not be suitable using the wave overhangs.

Shape is there, messed up on the perimeter. Material warps a lot even though it looks like it shouldnt.

Not good at all, seems like the waves do not adhere to each other.

Still not good, very similar to last PHA sample.

Line spacing might be too high, as the adhesion between layers is suffering (Classic ABS). Might be that this is printed in an open printer, will try later in an enclosed one. Warping is definitely less than the other ABS sample.

It is getting there, still testing settings.

First time ABS, printed in open air on the BBL A1 Mini. Layer adhesion is very good, only in the extremities there is some artifacting. Warps a lot though

Failed, not sure why yet exactly

It is getting there, on the good parts of the print, the curling is extreme

Not a lot to say for this one

Does not look well at all. It looks like a fly got stuck between two of the layers. Don't know exactly what needs changing yet.

Too much.

Even more warping caused by the line spacing.

Increased the line spacing too much, warping as a result of it.

Tried to mitigate the gaps by increasing the perimeter overlap. Might be the best sample so far. Waves are good and adhere well with each other.

Even bigger gaps near the perimeter, starting to become a problem especially in the inner corner. Waves once again look nice

Bigger gaps starting to form near the perimeter due to line spacing. Waves look nice

Print overall is very good, slight warping in the overhang caused some overextrusion in subsequent layers.

Not quite perfect, quite a bit of warping in the extremities. Between a 4 and 5 I would say

Even better than last sample. Warping only near the smaller wave segments but minimal. Tuning line spacing such that there is barely the adhesion to suspend the material mid air might give the best results. However, there are gaps starting to form near the perimeter as a result of the line spacing.

Very good sample, increased the line spacing to above 0.4 to 0.42. The only issue on this sample is the warping in the area with concentrated waves.

Small amount of layer separation, as seen in photo 2. Minimal warping, only near the smaller waves. On the top side, the waves and perimeter do not properly connect, but can already be seen in the gcode viewer.

Not a lot of warping, though there are some spots where there are gaps between tracks and the perimeter (See photo 2).

Better overall compared to the last. Warping similar to last as well. The rough surface is less than before.

Adhesion between base and overhang weak, line spacing causing issues near perimeter. Warping is less than last sample.

The connection between the base of the model and the wave overhang is weak. A wavy pattern can be identified on the bottom and top surface again. Significant warping again

First decent PLA-CF print. There is a weird texture on both the bottom and top surface, which could be the cause of too much overlap. Layer adhesion is better than PTSample25. A lot of warping is still observed.

Tried with PLA-CF, no layer adhesion at all.

Print quality overall very good, the main issue here is the amount of warping.

Only a slight disconnection between the perimeter before the curve. Warping is the bigger issue

Tried upping the wave flow to see effect. Apart from a small disconnection in the inner corner of the sample, the print looks great. A lot of warping is present though.

Noticed underextrusion and simply no connection between the start of the curve in the overhang and the perimeter. A lot of warping present.

A lot of overextrusion, very much visible on both the top and bottom. Warping caused the nozzle to interfere when printing the perimeters, causing the sample to fly off the build plate. Accidentally used the wrong filament profile, temperatures were higher than normally used.

Rough perimeter and disconnection between waves and perimeter. A lot of warping but shape is there

Apart from the same artifact that appeared during the last sample, the print quality is overall very good, a lot of warping is identified.

Tried another printer and the new Orcaslicer version for the first time. Noticed a lot of underextrusion with the same converted settings as PTSample 8 and 14. Also a new artifact appeared between corners.

Almost perfect, small disconnections between the perimeter, tried replicating the same result as PTSample8 and PTSample14, but with different filament

Very similar results to 13, seems to pull back on the material

Almost perfect again, wanted to replicate the result from PTSample8, same result is found.

Same weird starting lines, looks like overextrusion but the parameters are roughly the same. *PATTERN USED IS "SMART", unlike photo*

Weird starting lines, overall not very good quality though shape is properly retained

Still shows signs of overextrusion, overall looks clean, nozzle still dragging across the layers.

Shows signs of overextrusion, but overall looks clean. Nozzle is dragging across the layers.

Shows signs of overextrusion, nozzle is dragging across the layers, causing them to disconnect near perimeter

Almost perfect, not quite, perimeter on a different level than the rest of the overhang

Waves not connected to the perimeter on a couple points

Waves not connected to the perimeter on a couple points

Generally dimensional inaccurate, perimeter on different level, edges not connected

Very poor quality, not dimensionally accurate at all, a lot of underextrusion.

Very poor quality, not dimensionally accurate at all. A lot of underextrusion

Takes somewhat of a form, but still does not resemble the model

Does not take form at all. Poor adhesion between layers