Layer Separation and Splitting

In 3D printing, objects are created by stacking layers of material one on top of the other. Each new layer is printed on the previous one, eventually forming the desired 3D shape. For a strong, durable part, it’s essential that each layer bonds well with the one beneath it. If this bonding is insufficient, the printed part may experience splitting or separation between layers.

Common Causes and Solutions:

Layer Height is Too Large

Most 3D printer nozzles range between 0.3 - 0.5mm in diameter, which allows them to extrude very fine layers of plastic capable of creating intricate details. However, these small nozzles also limit how thick each layer can be. When printing a new layer, it must be pressed against the one below it to ensure a strong bond. Generally, the layer height should be about 20% smaller than your nozzle’s diameter. For instance, if you’re using a 0.5mm nozzle, you’ll want to keep your layer height at or below 0.4mm. Exceeding this can prevent proper adhesion between layers, leading to separation. If your layers aren’t sticking together, check that your layer height is appropriate for your nozzle size. Try reducing the layer height to improve bonding.

Print Temperature is Too Low

The print temperature significantly impacts how well the layers bond. Warmer plastic adheres more effectively than cooler plastic. If your layers are separating and you’ve already confirmed that your layer height is appropriate, the issue could be that the filament needs a higher temperature for better adhesion. For example, when printed at 190°C, ABS plastic will likely result in weak layer bonding as ABS typically needs to be extruded at 220-235°C to achieve a strong bond between layers. If you suspect the temperature is the problem, double-check the recommended printing temperature for your filament and try increasing it by 10°C to see if adhesion improves.