Cooling

Cooling settings directly influence print quality, structural integrity, and material behavior. Proper configuration ensures optimal solidification of layers, minimizes defects in overhangs/bridges, and balances speed with part durability. Active cooling fans are critical for materials like PLA but require careful calibration to avoid warping or delamination in temperature-sensitive filaments.

Cooling Requirements by Material

PLA and Cooling-Dependent Materials

• Active Cooling: Essential for clean overhangs, bridges, and surface quality.

• Fan Speed: Typically 100% for most PLA prints to prevent layer curling and sagging.

• Exceptions: Large, thick PLA parts may tolerate lower fan speeds (70–80%) to reduce warping.

High-Warping Materials (ABS, ASA, PC)

• Cooling Strategy: Minimal or no active cooling for medium/large parts to maintain layer adhesion.

• Exceptions: Enable cooling (20–50%) for small features (e.g., pins, thin walls) to prevent deformation.

• Enclosure Use: Maintains ambient temperature, reducing reliance on active cooling.

Flexible Filaments (TPU, TPE)

• Cooling Approach: Limited cooling (0–30%) to prevent nozzle jams and ensure layer bonding.

Slicer-Specific Cooling Parameters

Fan Activation and Layer Control

• Initial Layers: Disable cooling for the first 0.5–0.7mm to enhance bed adhesion.

• Variable Fan Speeds:

  • Bridges/Overhangs: 100% fan speed for rapid solidification.

  • Dense Infill Areas: Reduce fan speed (50–70%) to minimize warping.

Minimal Layer Time

• Function: Pauses between layers to allow cooling if print time falls below a threshold.

  • Typical Range: 5–15 seconds (lower for PLA; higher for ABS in enclosures).

  • Lift Head: Raises the nozzle during pauses, reducing heat transfer but increasing stringing.

Layer Height and Cooling Efficiency

• Thin Layers (0.1–0.2mm): Improve overhang quality by reducing unsupported material.

• Thick Layers (≥0.3mm): Require longer cooling times or lower print speeds.

Advanced Cooling Techniques

Auxiliary Cooling Systems

• Purpose: High-speed printers (e.g., Bambu Lab X1, Voron Trident) use secondary fans to enhance airflow for rapid cooling.

• Implementation:

  • Dual-Sided Fans: Ensure even cooling for complex geometries.

  • Nozzle-Specific Ducts: Direct airflow precisely to overhangs or bridges.

Dynamic Cooling Adjustments

• Overhangs/Bridges: Automatically increase fan speed in slicers (e.g., PrusaSlicer, Cura) for targeted cooling.

• Material-Specific Profiles: Save custom cooling settings for filaments with unique requirements (e.g., PETG at 50–80% fan speed).

Geometry-Driven Cooling

• Small Features: Prioritize cooling for towers, spikes, or fine details to prevent melting.

• Large Flat Surfaces: Use monotonic ordering to align layer lines and improve surface consistency.

Cooling and Overhang Optimization

Critical Parameters for Overhangs

1. Fan Speed: Maximize airflow (100%) to solidify material before sagging.

2. Print Speed: Reduce to 5–20mm/s for steep overhangs (≥45°).

3. Temperature: Lower nozzle temperature by 5–10°C to reduce filament viscosity.

4. Layer Height: Use ≤0.2mm layers to minimize overhang angles.

Slicer-Specific Strategies

• Cura: Enable "Bridge Settings" for adaptive cooling and speed adjustments.

• PrusaSlicer: Adjust "Overhangs Speed" and "Bridge Fan Speed" in filament settings.

Troubleshooting Cooling Issues

Warping/Delamination

• Causes: Excessive cooling on ABS/ASA; uneven airflow.

• Solutions:

  • Disable cooling for initial layers.

  • Use enclosures and minimize chamber drafts.

Poor Overhang Quality

• Causes: Insufficient cooling, high print speed, or incorrect nozzle temperature.

• Solutions:

  • Increase fan speed and reduce print temperature.

  • Reorient the model to face overhangs toward cooling fans.

Nozzle Temperature Fluctuations

• Causes: Cooling fans blowing directly on the heater block.

• Solutions:

  • Install a silicone sock on the heater block.

  • Adjust fan duct orientation to target extruded material, not the nozzle.