Uncured resin and hollow cavities created in the prints

We recently got a Form 1+ in our lab. For the most part, the surface quality and detail is great, but there are some significant issues with the prints so far. There are areas of uncured resin and hollow channels underneath the surface which have led to holes and cracked areas in the model. Since we got the printer, I printed the butterfly clip and 3 separate copies of the head that is in the attached. Each copy was printed separately with a different orientation. The most recent print has the least issues but is still not usable. I teach at the University of South Florida and the printer is for our lab.

Additionally, I never received the rinse basket with the finishing kit, so I have just had to dip it in the alcohol and agitate it. Has anyone had similar problems and found ways to solve the issue? Also, do some of the FL resin cure better than others?

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Hi

Those issues look similar to the trouble I had with my first form1 and that was ultimately diagnosed as a laser issue - have you raised a support ticket? Also you might want to run the diagnostic:

To access the diagnostic test, please make sure your computer is connected to your Form 1.

  1. Open the Windows command line prompt by searching “cmd” in the Windows start menu, or pressing Windows Key+R and searching “cmd”.
  2. In the command line prompt, type the following line exactly:
    For Windows XP and Vista:
    “C:\Program Files\Formlabs\PreForm\PreForm.exe” -diagnostic
    For Windows 7 and above:
    “C:\Program Files (X86)\Formlabs\PreForm\PreForm.exe” -diagnostic
    If PreForm is installed in a different location on your computer, please replace its exact file path in the quotes above.
  3. When you hit Enter, PreForm will automatically open with an additional Diagnostic drop-down option in the menu bar. You can click “Apply” or Exit the Print Setup window.
  4. From the Diagnostic option in the menu bar, select “Laser Spot Test” and follow the instructions that ask you to cover the tank area with a piece of paper.
  5. The laser should turn on for about 10 seconds. Please take one or two pictures of the laser spot on the paper and send them to me. It is best if I can clearly see the spot on the full width of the paper.

Hope this helps.

Do you have any screenshots or a copy of the .form files? I’d be curious to take a look at the different orientations/go through the slicer. Also, is the head supposed to be solid or is the hair supposed to have hollow features?

If the answer is no to the latter, there are a few possible causes for this hollowing/blistering:

  • Improperly mixed resin: Make sure to shake up the resin bottle thoroughly before using. I also use the scrapper to agitate the any resin in the tank
  • Problems with the mesh of the model: Use the slicer and go through layer by layer to make sure there are no anomalies/weird artifacts that shouldn’t be there. Netfabb(which runs in the backround of PreForm) usually does an incredibly good job of checking and fixing any problems with the mesh of an object but its always good to double check.

Per Jason’s suggestion,checking the laser spot is a good idea. However, given the quality of the face/other smooth parts of the object I have my doubts that it is the laser.

Hope this helps. Let me know if you have any more questions.

Hi Jason

Thanks. I did raise a support ticket. They said I should here back from them with suggestions tomorrow. I haven’t tried the diagnostic yet, but that did get me to look to see issues others were finding with it. After I get the feedback from them, if I am having the same issue I am going to runt that test and post it.

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Cool, oh, don’t post any pictures to me - the list came to me via tech support and I just copied and pasted - but of course you already knew that :-s

Hi Clark

Thanks. I did look at the slicing before printing, I saw a very small issue in the ears so I created additional supports for them. The hair is not supposed to be hollow. There is a hollow cavity that is more central to the head but it is not too near to head and the overall shell is pretty thick except for the area around the neck. I did shake the resin moderately for about 15 seconds, but I’m not sure If I should have done more. I used the scraper to check the optical clarity of the tank before printing but no additional stirring. However, all three prints were done within 5 days of having a brand new printer, so the resin was not sitting for long. I used Netfab before importing the models into the printer, so there were no error messages on import. I attached images of the orientations from each of the prints in the order that I printed them. The last one was the most successful. After the first one, I also thickened the shell a bit. Thanks for all of your feedback. These are all giving me things to look out for.