Print Quality Optimization

Learn how to diagnose, fix, and prevent common print quality issues to achieve professional results every time.

Understanding Print Quality#

Print quality in resin 3D printing refers to how accurately your printed object matches the intended design. High-quality prints have:

• Smooth surfaces without visible layer lines
• Accurate dimensions that match the original model
• Strong layer adhesion without delamination
• Clean details with sharp edges and features
• Consistent results across multiple prints

Why Quality Matters#

• Professional appearance for display or commercial use
• Functional accuracy for parts that need to fit together
• Time savings from fewer failed prints
• Material efficiency from optimized settings
• Customer satisfaction for commercial applications

Common Quality Issues and Solutions#

1. Layer Lines and Surface Roughness#

What You’ll See#

• Visible horizontal lines across surfaces
• Rough, textured surfaces instead of smooth ones
• Uneven layer heights
• “Stair-stepping” on curved surfaces

Root Causes#

• Layer height too thick for the detail level needed
• Insufficient anti-aliasing settings
• Poor layer adhesion causing uneven surfaces
• Incorrect exposure times for the resin

Solutions#

Step 1: Optimize Layer Height#

1. Go to Profiles → Select your resin profile
2. Set Layer Height based on your needs:
   • High detail: 0.025-0.05 mm
   • Standard quality: 0.05-0.075 mm
   • Fast printing: 0.075-0.1 mm
3. Test with a small model to verify quality improvement

Step 2: Enable Anti-Aliasing#

1. Find Anti-Alias 3D → Set to 1 (enabled)
2. Set Anti-Alias Threshold to 0.5 (start with default)
3. Print a test model with curved surfaces
4. Adjust threshold if needed (lower = smoother but slower)

Step 3: Optimize Exposure Settings#

1. Check cure time for your resin type
2. Verify resin temperature (20-25°C recommended)
3. Test different exposure times with calibration models
4. Document successful settings for future reference

2. Poor Layer Adhesion#

What You’ll See#

• Layers separating during printing
• Weak, brittle prints that break easily
• Gaps between layers
• Print failures partway through

Root Causes#

• Insufficient cure time for the resin
• Poor resin quality or contamination
• Incorrect temperature affecting resin properties
• Inadequate support structures

Solutions#

Step 1: Optimize Cure Time#

1. Start with manufacturer recommendations for your resin
2. Test with calibration models to find the sweet spot
3. Increase cure time by 1-2 seconds if layers don’t stick
4. Monitor resin temperature during printing

Step 2: Enable Multi-Cure#

1. Find Multi Cure Gap → Set to 0.1 mm
2. Set Cure Passes to 2 (start with 2 passes)
3. Test with a small model to verify improvement
4. Increase passes to 3-4 for difficult materials if needed

Step 3: Check Support Configuration#

1. Verify support density is adequate
2. Check support thickness for strength
3. Ensure proper support placement on overhangs
4. Test support removal after printing

3. Dimensional Inaccuracy#

What You’ll See#

• Parts don’t fit together properly
• Measurements don’t match the model
• Inconsistent sizing across different prints
• Assembly problems with multi-part models

Root Causes#

• Incorrect resolution settings for your printer
• Poor calibration of the build platform
• Resin shrinkage not properly compensated
• Temperature fluctuations during printing

Solutions#

Step 1: Calibrate Display Resolution#

1. Go to Display Calibration in settings
2. Use boundary calibration to verify full display coverage
3. Check resolution settings match your hardware
4. Test with known dimensions (calibration cube)

Step 2: Compensate for Resin Shrinkage#

1. Measure printed parts with calipers
2. Calculate shrinkage percentage compared to model
3. Adjust scaling in your slicing software
4. Test and refine until dimensions are correct

Step 3: Stabilize Environment#

1. Maintain consistent temperature (20-25°C)
2. Avoid drafts and air currents near your printer
3. Use consistent resin from the same batch
4. Monitor humidity and keep it stable

4. Surface Defects and Artifacts#

What You’ll See#

• Pockmarks or holes in surfaces
• Rough patches or inconsistent finish
• Support marks that don’t clean up
• Uneven surface quality across the model

Root Causes#

• Insufficient support density in problem areas
• Poor resin quality or contamination
• Incorrect exposure settings for the material
• Build platform issues affecting adhesion

Solutions#

Step 1: Optimize Support Settings#

1. Increase support density in problem areas
2. Adjust support thickness for better strength
3. Use different support types for different areas
4. Test support removal to find optimal settings

Step 2: Check Resin Quality#

1. Use fresh, uncontaminated resin
2. Filter resin if it contains particles
3. Store resin properly to avoid degradation
4. Check expiration dates on resin bottles

Step 3: Fine-tune Exposure#

1. Test different cure times with small models
2. Verify exposure consistency across layers
3. Check for over-curing which can cause surface issues
4. Document successful settings for each material

Quality Optimization Workflow#

Step 1: Baseline Assessment#

1. Print a calibration model (20x20x20mm cube)
2. Measure all dimensions with calipers
3. Photograph surfaces for visual assessment
4. Document current settings and results

Step 2: Systematic Testing#

1. Change one variable at a time to isolate issues
2. Test with consistent models for comparison
3. Measure and document all results
4. Identify the most impactful improvements

Step 3: Profile Optimization#

1. Create optimized profiles for different quality levels
2. Test profiles thoroughly before production use
3. Document successful configurations for team use
4. Regular profile updates based on new learnings

Step 4: Continuous Monitoring#

1. Monitor print quality on every print
2. Track quality metrics over time
3. Identify trends and potential issues
4. Proactively adjust settings before problems occur

Advanced Quality Techniques#

Adaptive Slicing for Quality#

What It Does#

Automatically adjusts layer thickness based on model geometry, providing optimal quality where needed while maintaining efficiency.

Configuration#

1. Enable Adapt Slicing: Set to 1
2. Set Min Layer Height: Use 0.025 mm
3. Set Max Layer Height: Use 0.1 mm
4. Test with complex models to verify effectiveness

Benefits#

• Better detail in complex areas
• Faster printing in simple areas
• Consistent quality across the entire model
• Automatic optimization based on geometry

Multi-Cure for Enhanced Quality#

What It Does#

Performs multiple curing passes per layer, improving adhesion and surface quality.

Configuration#

1. Set Multi Cure Gap: Use 0.1 mm
2. Set Cure Passes: Start with 2, increase if needed
3. Monitor print time impact
4. Test quality improvement with challenging models

When to Use#

• High-quality requirements for professional use
• Difficult materials that need extra curing
• Complex geometries with challenging features
• Production quality standards

Anti-Aliasing for Smooth Surfaces#

What It Does#

Smooths edges and reduces stair-stepping for professional-quality surfaces.

Configuration#

1. Enable Anti-Alias 3D: Set to 1
2. Set Threshold: Start with 0.5, adjust as needed
3. Test with curved surfaces to verify improvement
4. Balance quality vs. speed for your needs

Best Applications#

• Curved surfaces and organic shapes
• Display models where appearance matters
• Professional applications requiring smooth finish
• High-detail models with fine features

Quality Monitoring and Maintenance#

Regular Quality Checks#

Daily Monitoring#

1. Check first layers of every print
2. Monitor print progress for obvious issues
3. Verify resin level and quality
4. Clean build platform between prints

Weekly Assessment#

1. Print calibration models to verify settings
2. Check surface quality of recent prints
3. Measure dimensional accuracy with known models
4. Review and update quality settings

Monthly Maintenance#

1. Deep clean build platform and FEP
2. Calibrate display and check resolution
3. Update profiles based on learnings
4. Review quality metrics and trends

Quality Metrics to Track#

Dimensional Accuracy#

• X, Y, Z measurements vs. model dimensions
• Consistency across multiple prints
• Assembly fit for multi-part models
• Tolerance compliance for functional parts

Surface Quality#

• Surface roughness measurements
• Layer line visibility assessment
• Support mark cleanup effectiveness
• Overall finish appearance

Print Reliability#

• Success rate percentage
• Failure types and frequency
• Print time consistency
• Material usage efficiency

Troubleshooting Quality Issues#

Problem: Inconsistent Quality#

Check These Areas#

1. Temperature stability during printing
2. Resin consistency and age
3. Profile settings are properly saved
4. Hardware calibration is current

Solutions#

1. Stabilize environment with climate control
2. Use consistent resin from same batch
3. Verify profile settings are saved correctly
4. Re-calibrate hardware if needed

Problem: Quality Degradation Over Time#

Check These Areas#

1. FEP film condition and wear
2. Build platform surface preparation
3. Resin contamination or degradation
4. Hardware wear and tear

Solutions#

1. Replace FEP film if worn or damaged
2. Re-prepare build platform surface
3. Use fresh, clean resin
4. Maintain hardware according to schedule

Problem: Specific Areas Have Poor Quality#

Check These Areas#

1. Support configuration in problem areas
2. Model orientation and overhangs
3. Layer height consistency across the model
4. Exposure settings for different areas

Solutions#

1. Increase support density in problem areas
2. Adjust model orientation to minimize overhangs
3. Use adaptive slicing for consistent quality
4. Fine-tune exposure for challenging areas

Best Practices for Quality#

1. Start with Quality#

• Don’t sacrifice quality for speed initially
• Perfect your settings before optimizing for speed
• Quality is more important than fast printing
• Good quality saves time in the long run

2. Systematic Approach#

• Test one variable at a time to isolate issues
• Document everything including failures
• Learn from each print to improve the next
• Don’t make multiple changes simultaneously

3. Consistent Environment#

• Maintain stable temperature throughout printing
• Use consistent materials and supplies
• Regular maintenance prevents quality issues
• Monitor conditions during printing

4. Continuous Improvement#

• Track quality metrics over time
• Identify trends and potential issues
• Update procedures based on learnings
• Share knowledge with your team

Next Steps#

Once you’ve optimized print quality:

• Profile Management - Create optimized profiles for different materials
• Advanced Slicing - Fine-tune slicing for optimal results
• Elephant Foot Mitigation - Perfect base layer quality
• Machine Configuration - Optimize hardware settings

Related Topics#

• Profile Management - Configure resin-specific settings
• Advanced Slicing - Fine-tune slicing parameters
• Elephant Foot Mitigation - Perfect base layers
• Machine Configuration - Hardware setup and calibration

Edit this page on GitHub