Pillowing

pillowing unsupported portion of a horizontal surface is stretched out of position during printing pillowing how to identify pillowing can be diagnosed as follows pillowing occurs on surfaces that are horizontal, or parallel to the platform, during printing the defect appears at the center of the surface's span, between supports pillowing appears as a pillow, or convex surface, between supports looping docid\ vuky2xmsmex2mqztp2e2y and fanging docid\ zqdgujoitnihiqplrqdvt are defects that arise from the same issue but appear at different locations or features at horizontal struts or nodes, respectively cause inconclusive troubleshooting it is recommended that you review all the possible solutions before taking action to ensure you are pursuing the best course of action if the best course of action is not apparent, try the troubleshooting options in the order listed refer part defects for more tips print preparation or part design adjustments the following solutions will address print or part related causes of the defects choose among the suggested actions below and select the best approach for your application usually only one type of adjustment is needed orientation reorient the part to minimize horizontal surfaces supports may be needed with a new orientation orientation supports add supports to the affected overhangs supports design add gussets to stabilize overhangs that are pillowing tilt horizontal overhangs 40 degrees +/ so that they are self supporting reference dls design guidelines for unsupported angles per resin design print plan adjustments reference print plan adjustments for guidance on the following parameters 1 pump up parameters pump height parameters minimum pump height minimum distance from peak distance from peak multiplier platform speed parameters motor up speed 3 pump down parameters platform speed parameters motor down speed if problems persist, please reach out to carbon support explanation & causes explanation pillowing occurs when a portion of a horizontal surface is stretched out of position during printing because of how the slicing plays out over the geometry, only a thin portion of this surface is cured before the next slice captures more of the geometry part sliced to capture a portion of a horizontal surface this makes the affected partial surface, between supports, a thin, unsupported overhang which is weak during the pump up stage while the platform moves up, the weak partial surface is temporarily held in place by the surface tension of the dead zone, pulling it out of shape before the tension is broken when the platform moves back down, the surface is even weaker in its stretched out shape, leaving it susceptible to be pushed in the other direction under the pump down forces this is the position the malformed part stays in when the next slice cures, leaving it to appear as a pillow between supports pillowing on a printing slice reference dls printer dynamics docid\ u7xyytjydp3bvsyy2qkcu for more information on the stages of printing a slice z dimensions for pump height and slice thickness are exaggerated in the diagrams above for visibility causes print preparation or part design how the part is oriented , supported , or designed is causing the defect print preparation or part design cause root issue problem why defect presents orientation part is oriented to have surfaces printing horizontally (relative to platform) surfaces may be sliced to be thin and susceptible to pillowing supports part requires more supports at pillowing overhangs surfaces may be sliced to be thin and susceptible to pillowing design part is designed to have flat surfaces surfaces may be sliced to be thin and susceptible to pillowing print plan adjustments print plan adjustments print plan adjustments adjust the print plan to optimize mid to high volume production and/or address part defects in doing so, adjustment may both prevent or cause defects below are adjustments that can cause this defect printing stage parameter type type of adjustment why defect presents 1 pump up pump height increase increase increased pump height provides more space for the weak surface to be stretched out of shape 1 pump up platform speed increase increase increased motor up speed provides less time for the weak surface to break from the dead zone surface tension while also increasing suction forces 3 pump down platform speed increase increase increased motor down speed increases the pump down forces that push the weak, stretched surface out of position