Optimizing Z Seam for Perfect 3D Prints

When printing an object with smooth sides (not in vase mode), you might notice a line of bumps running down the side of your print. This phenomenon, often misnamed as blobs or zits, is more accurately known as a Z seam . A Z seam typically appears as a single line spanning the entire Z-axis of your model.

Z seams are present on most 3D prints, but their visibility and severity can vary based on factors like the size and shape of the model. They are especially noticeable on tall and circular objects because taller parts have longer seams, and the smooth walls of circular parts make seams more visible.

While a Z seam doesn’t usually affect a part’s functionality, it can be bothersome, particularly for display pieces like vases or cosplay parts. Fortunately, there are several ways to reduce the visibility of Z seams. This article will discuss what causes Z seams, how to prevent them, and Cura settings you can use to control and hide the Z seam, enhancing the overall appearance of your 3D prints.

Causes

The Z seam is a print quality issue that occurs in almost every print, but its severity depends on several factors. Let's delve into the extrusion process to understand it better.

A Z seam forms when the printhead, specifically the nozzle, moves to the next layer. Just before this jump, extrusion halts, and the printhead pauses briefly while the Z-axis stepper motors lift it to the next layer. During this pause, excess filament can ooze from the nozzle due to built-up pressure in the hot end. When the extruder pauses, this pressure is released, causing a small outflow of material. This excess material sticks to the print at the pause location, creating the bumps of a Z seam.

The alignment of these bumps is determined by the slicer. Most slicers set the starting point of each new layer directly above the ending point of the previous layer, causing the bumps to align and form a visible Z seam. Although this alignment can be adjusted, placing the start and end points in the same location is efficient and helps limit print time. Shifting the start point doesn’t eliminate the built-up pressure, and moving the printhead across the print to start the next layer in a new location could cause stringing.

A Note on Cura 5.3 Some users reported strange slicing artifacts appearing as random Z seam blobs on curved surfaces after updating Cura to versions 5.3.0 or 5.3.1. Fortunately, developers addressed the feedback and identified the issue.

The problem seems to be fixed in Cura 5.7, the latest release at the time of writing. However, if you encounter similar artifacts in later versions, consider reverting to Cura 5.2 or earlier. If you suspect this issue and there is no new information on its cause, using an older version might help resolve the problem.

Prevention

There are two approaches to dealing with Z seams: preventing and hiding them. To prevent Z seams, you need to address the root cause, which is the pressure inside the hot end that releases excess material onto the print.

This pressure results from imperfect extrusions during the printing process, and preventing it can be challenging. The goal is to perfect your printer’s extrusion by tuning all contributing factors. Many slicer, firmware, and mechanical considerations affect extrusion, so this process can be time-consuming. Here are a few techniques and features to help prevent hot end pressure:

Calibrate your extruder (E-steps): Adjusting the E-steps ensures that your extruder motor extrudes accurately. A calibrated extruder ensures that when you extrude 10 mm of filament, precisely 10 mm enters the hot end. Adjust the flow rate: Also known as the extrusion multiplier, the flow rate determines the rate at which filament is extruded. It's best to tune this value after calibrating your extruder. Nozzle temperature: The hot end temperature is crucial for proper extrusion. Higher temperatures allow material to melt and flow quickly, but too high a temperature can lead to over-extrusion, making the Z seam more noticeable. Print speed: Lowering the print speed gives the filament more time to extrude, helping to limit hot end pressure. By carefully calibrating these factors, you can reduce or prevent Z seams and improve the overall quality of your prints.

Techniques to Prevent and Hide Z Seams Coasting: Coasting is a feature that instructs your printer to stop extruding material while continuing to move during the final portion of a layer. The idea is that the residual pressure in the hot end will complete the extrusion. While coasting can help, setting the value too high might create small gaps at the end of layers when the material runs out too soon. Retraction: Retraction is a feature in your 3D slicer that commands the extruder to retract filament from the hot end at the end of a nozzle move. This reduces hot end pressure during pauses, helping to prevent Z seams and reduce stringing. However, excessive retraction can cause nozzle jams. Retraction at Layer Change: This setting specifically retracts filament when the hot end moves to the next layer. It can increase print times and potentially cause issues if the retraction distance is too large, but it’s crucial for addressing Z seams. Wipe: Wiping moves the nozzle side to side after completing a layer, helping to relieve hot end pressure away from the print. This approach prevents the pressure from causing excess material to be deposited on the model, thus reducing Z seams. Linear Advance: Linear advance is a firmware feature that predicts hot end pressure and uses a set compression value (K) to keep extrusion consistent with print speed. While it doesn’t prevent pressure, it utilizes it effectively to maintain consistent extrusion. Additional Techniques to Improve Print Quality

Calibrate Your Extruder (E-steps): Adjusting E-steps ensures the extruder motor extrudes filament accurately. Proper calibration means that when you command 10 mm of filament, precisely 10 mm enters the hot end. Adjust the Flow Rate: Also known as the extrusion multiplier, the flow rate determines how much filament is extruded. Tuning this value after calibrating your extruder helps achieve optimal extrusion. Nozzle Temperature: The temperature of the hot end is crucial. Higher temperatures allow faster melting and flow, but too high a temperature can cause over-extrusion, making Z seams more visible. Print Speed: Lowering the print speed gives more time for the filament to extrude, reducing hot end pressure and improving print quality. Conclusion By utilizing these features and techniques, you can address the root causes of Z seams and enhance the overall quality of your 3D prints. Adjusting settings like coasting, retraction, and linear advance, along with careful calibration of your extruder, flow rate, nozzle temperature, and print speed, can significantly reduce or hide Z seams, leading to smoother, more professional-looking prints.

Optimizing Z Seam for Perfect 3D Prints

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