3D Printing

Overview

Research and documentation for 3D printing — from understanding print defects to calibrating every variable, and ultimately automating the entire process.

Printer

Spec	Value
Model	Prusa XL 5-tool
Build Volume	360x360x360 mm
Extruders	5 (multi-material capable)

Projects

• 3D Printer Auto-Tuner — Automatic calibration system using sensors, CV, and G-code automation
• Filament Spool Holder — All-in-one drybox, inline cleaner, and jam-safety cutter
• Filament Recycler — Recycle failed prints into usable filament with closed-loop quality control

Calibration Variables

The parameters that control print quality. Each one documented with what it does, why it drifts, how to calibrate it manually, and how the auto-tuner approaches it.

Printer-Specific (once / hardware changes)

Calibrate in this order — each step depends on the previous:

1. E-Steps — Extruder steps/mm, foundation of extrusion accuracy
2. Axis Steps/mm — Positional accuracy per axis
3. PID Tuning — Temperature control stability
4. Bed Mesh / ABL — Bed surface compensation
5. Probe Z-Offset — True first layer height
6. Input Shaper — Vibration compensation
7. Belt Tension — Motion system tension
8. Backlash Compensation — Direction reversal play
9. Skew Compensation — Axis perpendicularity
10. Max Acceleration / Velocity — Speed and acceleration limits

Filament-Specific (per spool)

Calibrate in this order after printer-specific is done:

1. Extrusion Temperature — Optimal melt temperature per filament
2. Flow Rate — Extrusion multiplier fine-tuning
3. Max Volumetric Flow — True speed limit for extrusion
4. Pressure Advance — Melt zone pressure compensation
5. Retraction — Anti-ooze filament pullback
6. Bed Temperature — Heated bed for adhesion and warping
7. Cooling / Fan Speed — Part cooling for overhangs and bridges
8. Speed Profile — Per-feature optimal print speeds

Anomalies

Common 3D printing defects — what they are, how they form, and which calibration variables cause them.

Extrusion Anomalies

• Under-extrusion
• Over-extrusion
• Stringing / Oozing
• Blobs / Zits
• Grinding / Stripping

Adhesion Anomalies

• Warping
• Elephant Foot
• First Layer Adhesion Failure

Motion Anomalies

• Ghosting / Ringing
• Layer Shift
• Z-Banding / Z-Wobble
• Backlash Artifacts

Surface Anomalies

• Layer Separation / Delamination
• Pillowing
• Scarring / Nozzle Marks
• Rough Overhangs
• Bridge Sag

Structural Anomalies

• Spaghetti
• Heat Creep
• Clogging / Partial Clog
• Wet Filament Artifacts
• Thermal Shock Cracking

Materials & Profiles

Material	Brand	Temp (Nozzle/Bed)	Status
PLA	-	-	Not configured
PETG	-	-	Not configured
TPU	-	-	Not configured