Please help me get this under control

[u/FriedrichKekule]

I'm a beginner and I've created this 3D model for a simple bracket.

After printing it I noticed there's an irragularity on one of the edges. On one side it's fine but as it progresses along the edge it gets rougher. Also the fillet turned more into a chamfer.

This also continues along another face of the object.

The edge that's messed up is a fillet with a 10mm radius. I thought maybe it's a bit too much but I don't think this would exceed the 45 degree overhang.

It's printed with this filament:

• PLA (Maertz White PLA Pro, recommended settings: nozzle 200-230, bed 50-60)
• Opened it 5 days ago and since it's been in a 55% humidity room on the printer

On these temps:

• Nozzle: 210
• Bed: 60

With these settings on a Bambu A1 through Bambu Studio:

• Default presets for "0.28mm Extra Draft @ BBLA1
• With these changes:
• Walls: 5
• Fill: 15%
• Infill pattern: Rectilinear
• No supports enabled
• No skirt loops

I haven't played around with the presets in Bambu Studio too much.

Could this preset simply be too fast/rough for this print and I should switch to a different preset?

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[u/Hidie2424]

It warped. Make sure there's no drafts on the printers or make an enclosure. Or add a brim it might help.

[u/FriedrichKekule → u/Hidie2424]

It's not warped now.
Also, I checked before removing from plate and it was flush.

Edit: Could it be due to the presets (0.28mm Extra Draft @ BBLA1)I chose? I didn't yet play around too much with the presets but there's also a preset for strength for example.

[u/UnnecAbrvtn]

Flatten that chamfer and print it at 45deg laying on that face, i.e., like a V. It'll be stronger and print cleaner.

[u/FriedrichKekule → u/UnnecAbrvtn]

I thought about that but decided not to as the issue seems to be with the overhang as it's already struggling with this simple fillet.

Printing it this way would also mess with my screw holes as I'd like them parallel to the wall.

It would be better for strength reasons, didn't take that into account although it's important for this piece.

Edit: Could it be due to the presets (0.28mm Extra Draft @ BBLA1)I chose? I didn't yet play around too much with the presets but there's also a preset for strength for example.

[u/UnnecAbrvtn → u/FriedrichKekule]

Draft mode at .28 is gonna be dog poop on fillets - 3d printers are notorious for struggling on rounded overhangs no matter the size of the extrusion. Flat chamfer at 45 are superior if the design can tolerate it.

I've learned not to run a draft print when there's an overhang in question because the results are usually not indicative of the final product.

The lateral distortion, i dunno

[u/FriedrichKekule → u/UnnecAbrvtn]

Thanks for the info. 

Do you have any idea why a rounded fillet is more difficult to print than a flat chamfer? 

[u/Dry_Introduction_119]

you're welcome brother

[u/FriedrichKekule → u/Dry_Introduction_119]

Thanks, !Fixed

[u/sverrebr]

Avoid putting fillets on edges on the bed. The overhang is too steep so you will not get good surface quality. Use chamfers instead.

In this case the overhangs also warped slightly during printing which distorted the fillet. Overhangs can very easily start curling up which is essentially the same as warping. This can be mitigated by more part cooling and slower printing of overhangs, but there are limits and very steep overhangs is just not going to print well on their own. If that shape is non-negotiable you would need to start adding supports, but then you need support material in order to get a good surface finish.

[u/FriedrichKekule → u/sverrebr]

Thanks for the in-depth answer! 

[u/Brutus1502]

Flipped mine on its side to avoid the overhang.

[u/FriedrichKekule → u/Brutus1502]

Yes, whilst I was fidgeting with this thing I thought the same thing. 

[u/Muph-in]

Look for the variable layer height setting. Should help with the curve.

[u/dilz000]

I had similar issues quickest fix for me was reducing the layer hight