I want to print a structure made from many small cylinders, akin to a bed-of-nails, with about 30mm length, a diameter of 1mm and a distance (centre to centre) of 2mm. This is necessary for an engineering research project in the field of microwave technology.
There are two unexpected things that happened and maybe someone has experienced something similar or can offer some advice on possible mitigation strategies.
Number 1: During the overnight printing process a peculiar symmetric pattern had formed from groups of four pins sticking together. They could be seperated quite easily before curing, but remained in the deformed position at that point.
(Point no. 1 surprised me especially, since a previous print in a Form 2 did not exhibit this behaviour)
Number 2: The curing process lead to another deformation of the pin structure, which resulted in an „outward spread“ of the tips of the pins. This gets more noticeable the further the pins are to the edge of the matrix.
Ultimately, it would be desirable to achieve as much uniformity as possible.
The layer thickness is 50 microns, Clear V4 was used and the model was printed without any support structures.
Thanks in advance!