How to Fix 3D Printing Layer Separation with 8 Easy Ways

Layer separation, or delamination, is a 3D printing issue where layers do not adhere well, resulting in visible cracks. This differs from poor first-layer adhesion, which causes a weak bond between the print’s base and the build surface. Delamination occurs due to weak interlayer bonds and can result from low temperatures, over-cooling, large layer heights, or hot end build-up.

In this article, we’ll explore potential causes and solutions to prevent delamination and ensure your 3D prints are strong and intact. Using a reliable printer like Creality's can also help achieve better results. Read more: 6 Easy Ways to prevent 3D Printer Layer Shifting

Tip #1: Clean the Hot End After extended use, your hot end and nozzle can become dirty or clogged, significantly impacting extrusion. A clogged nozzle reduces the material passing through, weakening layer bonds and causing issues like layer separation. To prevent this, regularly clean your printer’s hot end. Heat it to your usual printing temperature and use a metal pick to remove any build-up inside. Additionally, use a needle to clean around the nozzle. Replacements are inexpensive and easy to install if your nozzle is worn out. Regularly cleaning your hot end and nozzle , even without visible issues, acts as a preventative measure, ensuring consistent and reliable 3D prints.

Tip #2: Lower Print Speed Our second tip is to lower the print speed to improve extrusion and reduce issues like layer separation. Printing too fast, especially beyond the filament manufacturer’s recommendations, can cause extrusion problems. High speeds mean filament flows quickly, but if the hot end temperature isn’t sufficient, layers won’t bond well. Slowing down gives the hot end more time to melt the filament and fuse layers properly. Adjust your print speed in 5-10 mm/s increments until it's about 50% of the original value. If layer separation persists, the issue is likely not speed-related.

Tip #3: Raise Hot End Temperature Our third tip for solving delamination is to raise the hot end temperature, which can improve extrusion. When the hot end temperature is too low, the filament doesn’t melt sufficiently, causing under-extrusion and weak layer bonds. Increasing the temperature ensures the filament flows better, enhancing the adhesion between layers.

A higher nozzle temperature can yield stronger parts, as verified by CNC Kitchen tests. More heat increases filament flow and bonding strength. However, too much heat can degrade the filament, weakening adhesion.

If you're experiencing under-extrusion, start by increasing the hot end temperature by 10°C. If delamination persists, continue raising the temperature in 5-degree intervals until the issue is resolved, or you reach the printer’s or filament’s temperature limits. If delamination continues, the hot end temperature likely isn't the cause. This adjustment can significantly improve print quality by ensuring better layer fusion.

Tip #4: Increase Flow Rate Related to the previous two solutions, our fourth tip is to increase the flow rate (sometimes called "Extrusion Multiplier") in your 3D slicer. Before adjusting this, ensure the E-steps on your printer are correctly set, as flow rate and E-steps are closely related.

The flow rate determines how quickly the extruder feeds filament into the hot end. Adjusting it is a common way to resolve extrusion issues like over- or under-extrusion, and it can also address layer separation. Increasing the flow rate pushes more filament through the nozzle, enhancing the bond between layers.

If you’ve noticed under-extrusion in previous prints, adjusting the flow rate is a good next step (after raising the temperature) to eliminate layer separation. Increase the flow rate in 5% increments until the problem is resolved or you begin to experience over-extrusion. If over-extrusion occurs, it means you’ve gone too far, and the flow rate likely isn’t causing your delamination issue.

Tip #5: Adjust Part Cooling Our fifth tip to combat delamination is to adjust, usually by decreasing, the cooling for your print. Excessive cooling can cause layers to separate, similar to how too much airflow can warp the first layer. Since heat is necessary for layers to bond, rapid cooling can prevent proper adhesion.

To fix this, lower your part-cooling fan speed in 10% increments until the issue is resolved or you start to experience other printing errors. Don’t hesitate to reduce the fan speed to 0%, especially for temperature-sensitive materials like ABS. Some users have found that using a fan with PETG can weaken layer-to-layer adhesion.

Airflow can come from your printer’s part-cooling fan or unintentional drafts. To test if over-cooling is causing layer separation, print a test part with a low fan speed in a controlled environment, such as a closed room or a makeshift enclosure. If layer separation stops, over-cooling is likely the issue, and you should consider building or purchasing an enclosure for your printer.

Tip #6: Decrease Layer Height Our sixth tip to combat layer delamination is to lower the layer height setting in your slicer. Layer height, the distance the printhead shifts along the Z-axis before starting a new layer, can influence layer adhesion. Simplify3D and other sources suggest that a high layer height can contribute to delamination.

Layer height is typically based on your nozzle diameter. For a 0.4-mm nozzle, a common layer height is 0.2 mm. While smaller layer heights provide more detail, larger heights can make parts stronger. However, if the layer height is too high, layers may not bond effectively, causing delamination.

If you're using a standard 0.4-mm nozzle with a layer height above 0.2 mm and experiencing layer separation, revert to a 0.2-mm layer height. If this doesn’t solve the issue, try a lower height, like 0.16 mm. If delamination persists even at 0.16 mm, the layer height is likely not the cause.

Tip #7: Replace (or Dry) Filament Certain filaments degrade in quality when exposed to moisture, so our next tip is to change or dry your filament . When filament absorbs moisture, it becomes harder to print with, increasing the likelihood of issues like layer delamination.

More hygroscopic materials, such as TPU, absorb moisture faster than others. If you’re using a highly hygroscopic filament or notice signs of moisture (like poor print texture), try printing with a different spool before proceeding with other solutions.

Using dry filament helps prevent layer delamination and improves print quality. You can either use a new spool or dry your current one. To maintain the filament's condition after drying, store it in an airtight container to prevent moisture absorption. By ensuring your filament is dry, you can achieve better layer adhesion and more reliable prints. Learn more How to Choose Filament Dry Boxes and Dryers in 2024 , and find the best one for you.

Tip #8: Use a Wider Nozzle Lastly, if all else fails, switching to a nozzle with a wider diameter might help resolve your layer delamination issues. Nozzle diameter can significantly influence layer-to-layer adhesion, and generally, a larger diameter enhances adhesion. A wider nozzle lays down thicker lines of melted filament, increasing the surface area for the next layer to bond to. By increasing the layer height accordingly, fewer layers are needed to create the same part, reducing opportunities for layers to separate. Most 3D printers use a standard 0.4-mm nozzle. Consider switching to a 0.5-mm or 0.6-mm nozzle to try this solution. While this can be effective, we recommend trying other steps first to avoid an unnecessary purchase. However, a wider nozzle can negatively affect print precision. If you increase your nozzle diameter, don’t forget to adjust the nozzle temperature and flow rate to compensate for the increased extrusion. This adjustment can help enhance layer adhesion and reduce delamination.

By following these tips and utilizing reliable equipment like Creality's printers, you can significantly improve your 3D printing results and prevent issues like layer delamination.

How to Fix 3D Printing Layer Separation with 8 Easy Ways

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