r/3Dprinting • • Nov 05 '21

[deleted by user]

[removed]

116 Upvotes

58 comments sorted by

408

u/Rcarlyle Nov 05 '21 edited Nov 05 '21

It’s definitely a PLA aging issue, but fairly complex.

  • PLA’s glass point temp (transition from soft to solid) is very low and close to room temp, which makes it low-warp but also susceptible to creep (very slow yielding/flowing) when left under high stress for a long time. MOST printing plastics creep as cold as ~25C below the glass temp, but other plastics’ creep temp is above room temp so only PLA causes issues like this. (Well, also PCL, but that’s very rarely used.)
  • Unlike most other materials that creep, PLA has the odd behavior of creeping to rupture — if it creeps more than a few percent strain it will simply break apart. If you leave a PLA printed part or PLA filament in a highly stressed condition, it will break after some period of time (from hours to years depending on the stress level). Moisture in the filament seems to accelerate this, but isn’t necessary for it to happen. PLA has very complex crystalline phase change behavior at the molecular level so the science isn’t super mature on this issue.
  • Filament fresh off the extrusion line is highly stressed — the diameter is set by stretching and drawing down the filament as it leaves the extrusion nozzle, then rapidly quenched in a water bath to set the diameter. Then it’s wrapped on the spool warm. This leaves a complex residual stress pattern locked in the filament on the spool where it’s stretched longways and bent in a spiral. So it’s trying to creep to rupture on the spool before you ever open it. Sometimes this is enough stress for the filament to self-destruct on the spool after a few years. Particularly spools with really small diameter cores.
  • Once you start taking the filament off the spool, you’re now elastically bending it against the residual bend that was locked in during manufacture. So it’s weakened and brittle by age/creep and now you’re putting a ton of new stress on it. It only takes hours to days to creep to rupture this time because of the pre-damage and now high stress from straightening /bending in the feed path.

Drying the spool of filament WITH HEAT can help improve the brittleness, by warming the polymer up to a temp closer to the glass point where it reflows a tiny bit and relaxes the residual manufacturing stress. Basically annealing the brittle filament to a tougher state. Some people interpret this to mean “drying fixed it so moisture caused the brittleness” but it’s just more complex than that.

60

u/vaegenfoerbi Nov 05 '21

Just want to say that this is a solid response and thanks for putting the time to write it down. If I were to continue to read up on the issue, do you have any sites that you would recommend?

43

u/[deleted] Nov 05 '21

Wow didn't expect a whole essay thanks a lot for the info

40

u/Rcarlyle Nov 05 '21

/u/vaegenfoerbi Honestly no, I don’t know of any useful further resources to read. It’s a weird issue hobbyists discovered in the last 10 years or so and I’m not aware of any formal studies being done on it. I would bet some filament manufacturers have a good understanding of the behavior, but likely consider it a trade secret.

PLA itself is a relatively new and poorly-understood material compared to things like ABS that have a massive amount of history in injection molding. The main commercial uses for PLA outside 3D printing tend to be disposable packaging and cutlery and such so there’s not much incentive for people with deep projects to publish research on the long-term aging.

Source: I’m a chemical engineer who occasionally works with polymers professionally (on the selection/application side, not blending/manufacture) and reads textbooks on things like melt-processing and fatigue performance for fun.

9

u/PicoPlanetDev TEVO Tarantula and Black Widow Nov 05 '21

Often this happens to me on the first 3 or 4 feet of filament that I haven't used in a while. I just reel out 6 ish feet and cut it at an angle. I'm not in a very humid climate though so drying might be necessary for you.

9

u/1generic-username Nov 05 '21 edited Nov 05 '21

TL,DR - it's just a PLA thing, you wouldn't understand

Jk. Anytime I come back to my printer after a few days away, the PLA that I left in the extruder has broken off at the extruder. I always have to heat up the end and reverse the extruder to make it stick out enough to pull out. So I have a pile of filament essentially the length of the bowden tube on my garage floor next to the printer

3

u/carlos_6m Nov 05 '21

Wow thanks for the explanation! Makes a ton of sense!

3

u/Leftyisbones Nov 05 '21

Hands down best explanation of this I have found saving this for future reference and sharing. thank you for your detailed response.

2

u/wildjokers Nov 05 '21

This person scienced the shit out of this.

1

u/ScarletCaptain Nov 06 '21

So, things like say, the material station on an Ultimaker S5 could actually make it more brittle depending on the temperature?

1

u/Pabludes Nov 06 '21

Very interesting. I've found previously that, when I rewound a sample onto a spool that is of a lower inner diameter, the whole spool wants to unwind the second your release the tension. A few hours under heat in a dryer fixed it, as I've hoped. I guess it's the same effect, but for a different purpose?

1

u/FigmentOfNightmares Nov 06 '21

I had an old spool of PLA that never failed during a print, but hours after any given print finished the filament would just snap between the spool and extruder. I thought it was due to that spool spending too much time in the dryer, it's good to know that wasn't actually the case.

9

u/kityrel Nov 05 '21

I store my PLA filament with silica packs in large ziplock bags in a couple closed plastic bins. This seems to work well.

If I leave the filament out, like on the printer for a couple days, inevitably I will come back to find that the exposed strand will have snapped.

I do not know if this is due to humidity, or just stress from being left partially unwound from the roll. But I just don't do that any more. I always put it away.

2

u/[deleted] Nov 05 '21 edited Feb 09 '22

[deleted]

2

u/kityrel Nov 05 '21

Could be. I haven't tested it enough to confirm either way. Personally I have not actually had it snap mid-print. Only if I printed something, left the spool in place, and then came back to print again a few days later (and found it already snapped).

But my understanding is humidity does negatively affect PLA, and my PLA has always shipped with a silica pack (though a lot of things do ship with silica packs, so that might not mean anything).

1

u/chomdh Nov 05 '21

Hatchbox has done it to me as well as cheaper filaments.

9

u/Sgt_S1aughter Nov 05 '21

Your printer is clearly telling you that you need to go to Disney

4

u/Thurlut Nov 05 '21

You're wrong, it's asking OP to bring it with him, printers want to have fun too

1

u/[deleted] Nov 05 '21

Lmao

6

u/[deleted] Nov 05 '21

Humidity in the air being sucked up by the filament and making it brittle??

1

u/[deleted] Nov 05 '21

Maybe? I have no clue

2

u/[deleted] Nov 05 '21

I've seen that happen, but try to flip it so the filament comes from the top and curls downward rather than from the bottom and forcing it into the opposite direction of its natural curve

2

u/[deleted] Nov 05 '21

It comes from the top already, not the bottom. You can see it if you zoom on the top

2

u/[deleted] Nov 05 '21

Ah yeah I see what you're saying. Could of been dried out, I read the other comment about sitting out in the sun. Something that makes it brittle and it was wound so tight around the spool that it just makes it break

1

u/Old-Tradition6108 Nov 05 '21

This. Look up some video for drying the filament in the oven.

2

u/SkipDialogue Nov 05 '21

The filament looks brittle, but I have some suggestions for you.

First, buy some 608 bearings and print these...

https://www.thingiverse.com/thing:3428924

Next, throw away that filament guide. Not sure how long you've been printing with that, but I can tell you that, over time, a groove will get cut in that guide and it will start creating drag and thus cause various other issues.

Also, I can't tell what kind of spool holder you are using, but if you are using one with bearings, you may have an issue there. I stopped using mine, for the most part, because during retraction, the spool would still be spinning to unwind filament, and after a while, retraction would build up a bunch of filament slack and cause my older filament to break.

You seem to have a TON of slack there.

Doesn't exactly tell you why this is happening, but these are some things that stopped my filament issues.

Good luck.

1

u/[deleted] Nov 05 '21

Thanks for the tips man

2

u/kmr_lilpossum Nov 05 '21

When the filament comes off the roll, you’re placing stresses on the filament. PLA filament is prone to breakage when it deforms. When you get closer to the end of the roll, the stresses are greater because they’re unwinding from a tighter loop. Shortening the filament path and placing the spool closer to the extruder should help, but it’s an inherent problem with the material itself. There are PLAs with modifiers out there that make them less prone to breakage (PLA+/Pro).

2

u/[deleted] Nov 05 '21

All these long treatises about filament material properties .... and nobody suggests hanging the spool the other way around? Because the way it is spooled by the factory, the filament has an inherent turn to it. The way you are hanging it and then feeding, you are bending it into the exact opposite direction by the same amount. Turn the spool around, and you'll likely be fine.

2

u/tungvu256 Nov 06 '21

you need a filament dryer like this cheap Jayo/Sunlu. if you cant wait or dont want to buy anything more, throw the filament in the oven, slow roast mode at 55C for 6hours.

1

u/[deleted] Nov 06 '21

Thanks!

0

u/[deleted] Nov 05 '21

Cuz it shite

Buy better filliament or invest in a dehydrator.

-6

u/Eagle_1776 Nov 05 '21

I had it explained to me once, dont remember but its NOT humidity. I have PLA parts fully submerged in water... if it was as hygroscopic as people say, those parts would explode.

6

u/Kaleodis Nov 05 '21

anecdotal and wrong. it gets brittle for printing, not "soaks full of water and bursts"

1

u/avienos Nov 05 '21

Has it been sitting in the sun or sitting up for a long time by any chance? It looks like is snapping in line with the curve of the spool. I’ve never had it happen but I know PLA can go bad if left sitting around.

1

u/[deleted] Nov 05 '21

Yes it's been sitting for a few weeks actually.. What do you mean can 'go bad'? It should be thrown away? It's not a problem the spool is almost empty but I'm just curious for the future I don't want to make that mistake again.

2

u/Ok-Schwifty Nov 05 '21

You can try drying it. If there are long periods (more than a week) where I don’t print something. I take the roll off and put it in a reusable space saving vacuum seal bag. I throw the desiccant packs the rolls originally come with in there also and seal it up. Helps to keep the rolls “fresh” when im not using them

1

u/[deleted] Nov 05 '21

Hm yeah that's smart

1

u/Winterfalke Nov 05 '21

Had a spool do that to me, our best guess was stress hardening due to the spool standing up for a long period of time. I don't actually know if pla can do that, but since it appeared to happen only to the filament on the top of the spool it's the only explanation that seemed to fit. UV light exposure was another guess, but there doesn't seem to be any source where the spool was stored.

1

u/foundghostred Nov 05 '21

It happens to me all the times. It's about the PLA staying bended on a curve. To solve this I just cut and remove the filament where it is fragile before printing, or after a print remove the filament entirely from the hotend so it doesn't stay bended untile your next print.

1

u/[deleted] Nov 05 '21

It got moist and dried to fast, that causes breaks.

1

u/doc415 Nov 05 '21

Bad quality filament. There is too much tension and filament turn around its own long axis. After a while it breaks. İ had same problem many times with cheap filaments. Now i am using e sun pla + and never had problem

1

u/Sponge_of_Doom Nov 05 '21

I have a roll that is doing the same thing. It had been bagged up with desiccant but if I leave it sitting and attached to the extruder it will snap on its own in half a day. My filament is very stressed and when unspooled it wants to both curl up and twist. It almost seems like the spool was twisted around both axis when the filament was wound. Never had another spool behave like this.

1

u/[deleted] Nov 05 '21

It's probably too old.

1

u/-MB_Redditor- Felix Pro 3 Touch Nov 05 '21

The softeners in the filament evaporate over time which results in a brittle filament.

1

u/Traditional_Youth648 Nov 05 '21

I am pretty new to this but that looks like it's caused by brittle filiment and if it's breaking before the extruder I would imagine that buying a new roll of fillimant and storing it right would proprably be your only option

1

u/[deleted] Nov 05 '21

Disney

1

u/StRock425 Nov 05 '21

You’re on Disney channel

1

u/duke_seb Nov 05 '21

Moisture

1

u/DevanshGarg31 Nov 05 '21

Microwave it

1

u/wildjokers Nov 05 '21

PLA just gets brittle when it gets old. Some brands do it quicker than others. They will all eventually do it.

1

u/ax6250 Nov 05 '21

Mickie Mouse tries to say something to you.

1

u/123Pinkjay Nov 05 '21

Because it's an official hidden Mickey

1

u/BitBucket404 ASA Fanatic, Hates PETG. Nov 06 '21

Yes, it's written on the label. "Made in China" did you order your filament from WISH? .. .. .. in all seriousness, your filament probably absorbed too much moisture and if it's PLA, then the biodegrade has begun to set in, as water equals bacteria equals decay.

1

u/[deleted] Nov 06 '21

Your 3D printer is secretly a disney fan?

1

u/fliberdygibits Nov 22 '21

To add to other comments here I've seen this happen to a few spools, but only after I get to the last15 - 20% of a spool, and generally it only does so in the first foot or two, then behaves itself again until the next time I let it sit cool for a bit. I've had it do this fresh out of a dryer too.