formlabs Fuse 1, Manual

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Troubleshooting | 53
Error Cause Solution
Hard cake
• Unsintered powder fused into
a stiff cake
• Difficulty separating the part
from the unsintered powder
• Poor underlying surface finish
and loss of small negative
features
Bed temperature is too high. Check whether the IR sensor
housing has any laurolactam
built up in the sensor field of
view. Refer to section 6.4.2
Cleaning the IR sensor
housing for more information.
Warping
• Large scale curvature or a part
or section of parts
• Deviation from flatness
• Straightness spec
• Improper cooling procedure;
warping can occur during a
print if the part is allowed to
cool non-uniformly or if the
part is removed while still hot
• Parts printed too close to the
build chamber walls
1. Wait for parts to cool to
near room temperature
prior to removal from the
build chamber.
2. Move parts away from the
build chamber walls.
Pitting
• Surface imperfections on the
top-most surface on parts,
typically on small cross-
sectional regions
• In some cases, a hole that is
deeper or several layers thick
Bed temperature is too high. Check whether the IR sensor
housing has any laurolactam
built up in the sensor field of
view. Refer to section 6.4.2
Cleaning the IR sensor housing
for more information.
Melting
The powder on the surface of the
print is blackened due to melting.
Heaters heated the powder to
above its melting temperature.
The heaters or the IR sensor
may be malfunctioning.
Contact Formlabs Support or
a certified service provider for
additional guidance and provide
diagnostic logs.
Delamination
A sintered layer failed to adhere
to a previously sintered layer.
• Insufficient laser power
• Build chamber Z-motor
malfunction
Inspect the optical surfaces.
Fragile parts
• Parts with excessively low
strength
• Parts occasionally have a
lighter color and a more
granular surface texture than
normal
Insufficient sintering due to
attenuated laser power.
Inspect the optical surfaces.
Poor, mottled surface finish on
vertical surfaces
• Ratio of recycled to unused
powder is too high
• Grain size of recycled
powder is higher than unused
powder, causing variation
in melt temperature and
viscosity, leading to uneven
sintering in the bulk of the
model and poor surface finish
on the outside of the model
• Increase powder refresh rate
OR
• Dispose of degraded powder