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.

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