Reduce ABS Warping - 45 Degree Prints

ABS Filament has provided endless layer warping problems when 3D Printing. Having listened to many videos on the subject, one of the better ones explains the problem as uneven cooling that keeps stacking constantly shrinking layers. On the Sindoh 3DWORX1 this problem is evident on large rectangular long parts that are printed from the left corner to the right corner so that they fit.

Conventional wisdom suggests to use >=0.35mm first layers to promote bed adhesion. Unfortunately, on some 3DWORX1 units using the non-vendor produced Open Filament Mode this often results in a brim that begins to contract and curl up almost immediately.

In this print of a stepper motor fan shroud, although warping still occurs, the damage is mitigated, and a dimensionally accurate useable part is still produced.

• 1.75mm ABS Fillament
• 3DWOX1 3D Printer
• Tack Spray Glue

Spray the flexible print bed with a clear spray glue, wait for it to dry.

One solution to combat ABS warping is to:

• use slow printing speeds <=40mm/s
• 0.2mm layer heights
• 15% Infill
• 230 Degree Celsius Nozzle Temperature, 100 Degree Bed Temperature
• print the object at 45 degrees without supports. 

Here is a complete .ini file to import into Prusa Slicer

# generated by Prusa Slicer 2.4.2+win32 on 2024-01-01 at 16:55:45 UTC

[print:3DWOX1]

avoid_crossing_perimeters = 0

avoid_crossing_perimeters_max_detour = 0

bottom_fill_pattern = monotonic

bottom_solid_layers = 3

bottom_solid_min_thickness = 0

bridge_acceleration = 0

bridge_angle = 0

bridge_flow_ratio = 1

bridge_speed = 30

brim_separation = 0

brim_type = outer_only

brim_width = 5

clip_multipart_objects = 1

compatible_printers = 

compatible_printers_condition = 

complete_objects = 0

default_acceleration = 0

dont_support_bridges = 1

draft_shield = disabled

elefant_foot_compensation = 0

ensure_vertical_shell_thickness = 0

external_perimeter_extrusion_width = 0.45

external_perimeter_speed = 50%

external_perimeters_first = 0

extra_perimeters = 1

extruder_clearance_height = 20

extruder_clearance_radius = 20

extrusion_width = 0.45

fill_angle = 45

fill_density = 15%

fill_pattern = stars

first_layer_acceleration = 0

first_layer_acceleration_over_raft = 0

first_layer_extrusion_width = 0.42

first_layer_height = 0.2

first_layer_speed = 10

first_layer_speed_over_raft = 30

fuzzy_skin = none

fuzzy_skin_point_dist = 0.8

fuzzy_skin_thickness = 0.3

gap_fill_enabled = 1

gap_fill_speed = 20

gcode_comments = 0

gcode_label_objects = 0

gcode_resolution = 0.0125

gcode_substitutions = 

infill_acceleration = 0

infill_anchor = 600%

infill_anchor_max = 50

infill_every_layers = 1

infill_extruder = 1

infill_extrusion_width = 0.45

infill_first = 0

infill_only_where_needed = 0

infill_overlap = 25%

infill_speed = 30

inherits = 

interface_shells = 0

ironing = 0

ironing_flowrate = 15%

ironing_spacing = 0.1

ironing_speed = 15

ironing_type = top

layer_height = 0.2

max_print_speed = 40

max_volumetric_speed = 0

min_skirt_length = 0

mmu_segmented_region_max_width = 0

notes = 

only_retract_when_crossing_perimeters = 0

ooze_prevention = 0

output_filename_format = [input_filename_base].gcode

overhangs = 1

perimeter_acceleration = 0

perimeter_extruder = 1

perimeter_extrusion_width = 0.45

perimeter_speed = 40

perimeters = 3

post_process = 

print_settings_id = 

raft_contact_distance = 0.1

raft_expansion = 1.5

raft_first_layer_density = 90%

raft_first_layer_expansion = 3

raft_layers = 0

resolution = 0

seam_position = aligned

single_extruder_multi_material_priming = 1

skirt_distance = 6

skirt_height = 1

skirts = 0

slice_closing_radius = 0.049

slicing_mode = regular

small_perimeter_speed = 15

solid_infill_below_area = 70

solid_infill_every_layers = 0

solid_infill_extruder = 1

solid_infill_extrusion_width = 0.45

solid_infill_speed = 20

spiral_vase = 0

standby_temperature_delta = -5

support_material = 1

support_material_angle = 0

support_material_auto = 0

support_material_bottom_contact_distance = 0

support_material_bottom_interface_layers = -1

support_material_buildplate_only = 0

support_material_closing_radius = 2

support_material_contact_distance = 0.2

support_material_enforce_layers = 19

support_material_extruder = 1

support_material_extrusion_width = 0.35

support_material_interface_contact_loops = 0

support_material_interface_extruder = 1

support_material_interface_layers = 3

support_material_interface_pattern = concentric

support_material_interface_spacing = 0

support_material_interface_speed = 100%

support_material_pattern = honeycomb

support_material_spacing = 3

support_material_speed = 30

support_material_style = snug

support_material_synchronize_layers = 0

support_material_threshold = 48

support_material_with_sheath = 1

support_material_xy_spacing = 50%

thick_bridges = 1

thin_walls = 1

threads = 2

top_fill_pattern = monotonic

top_infill_extrusion_width = 0.4

top_solid_infill_speed = 15

top_solid_layers = 3

top_solid_min_thickness = 0

travel_speed = 60

travel_speed_z = 0

wipe_tower = 0

wipe_tower_bridging = 10

wipe_tower_brim_width = 2

wipe_tower_no_sparse_layers = 0

wipe_tower_rotation_angle = 0

wipe_tower_width = 60

wipe_tower_x = 180

wipe_tower_y = 140

xy_size_compensation = 0

[filament:3DWOX1]

bed_temperature = 100

bridge_fan_speed = 100

compatible_printers = 

compatible_printers_condition = 

compatible_prints = 

compatible_prints_condition = 

cooling = 1

disable_fan_first_layers = 3

end_filament_gcode = "; Filament-specific end gcode \n;END gcode for filament\n"

extrusion_multiplier = 1

fan_always_on = 0

fan_below_layer_time = 60

filament_colour = #29B2B2

filament_cooling_final_speed = 3.4

filament_cooling_initial_speed = 2.2

filament_cooling_moves = 4

filament_cost = 0

filament_density = 0

filament_deretract_speed = nil

filament_diameter = 1.75

filament_load_time = 0

filament_loading_speed = 28

filament_loading_speed_start = 3

filament_max_volumetric_speed = 0

filament_minimal_purge_on_wipe_tower = 15

filament_notes = ""

filament_ramming_parameters = "120 100 6.6 6.8 7.2 7.6 7.9 8.2 8.7 9.4 9.9 10.0| 0.05 6.6 0.45 6.8 0.95 7.8 1.45 8.3 1.95 9.7 2.45 10 2.95 7.6 3.45 7.6 3.95 7.6 4.45 7.6 4.95 7.6"

filament_retract_before_travel = nil

filament_retract_before_wipe = nil

filament_retract_layer_change = nil

filament_retract_length = nil

filament_retract_lift = nil

filament_retract_lift_above = nil

filament_retract_lift_below = nil

filament_retract_restart_extra = nil

filament_retract_speed = nil

filament_settings_id = ""

filament_soluble = 0

filament_spool_weight = 0

filament_toolchange_delay = 0

filament_type = ABS

filament_unload_time = 0

filament_unloading_speed = 90

filament_unloading_speed_start = 100

filament_vendor = (Unknown)

filament_wipe = nil

first_layer_bed_temperature = 100

first_layer_temperature = 240

full_fan_speed_layer = 0

inherits = 

max_fan_speed = 100

min_fan_speed = 35

min_print_speed = 10

slowdown_below_layer_time = 5

start_filament_gcode = "; Filament gcode\n"

temperature = 230

[printer:3DWOX1]

bed_custom_model = 

bed_custom_texture = 

bed_shape = 0x0,210x0,210x200,0x200

before_layer_gcode = 

between_objects_gcode = 

color_change_gcode = M600

cooling_tube_length = 5

cooling_tube_retraction = 91.5

default_filament_profile = 

default_print_profile = 

deretract_speed = 0

end_gcode = M104 S0 ; turn off temperature\nG28 X0 ; home X axis\nM84   ; disable motors\nM2 ;g-code end

extra_loading_move = -2

extruder_colour = ""

extruder_offset = 0x0

gcode_flavor = marlin

high_current_on_filament_swap = 0

host_type = octoprint

inherits = 

layer_gcode = 

machine_limits_usage = time_estimate_only

machine_max_acceleration_e = 10000,5000

machine_max_acceleration_extruding = 1500,1250

machine_max_acceleration_retracting = 1500,1250

machine_max_acceleration_travel = 1500,1250

machine_max_acceleration_x = 9000,1000

machine_max_acceleration_y = 9000,1000

machine_max_acceleration_z = 500,200

machine_max_feedrate_e = 60,60

machine_max_feedrate_x = 60,60

machine_max_feedrate_y = 60,60

machine_max_feedrate_z = 12,12

machine_max_jerk_e = 2.5,2.5

machine_max_jerk_x = 10,10

machine_max_jerk_y = 10,10

machine_max_jerk_z = 0.2,0.4

machine_min_extruding_rate = 0,0

machine_min_travel_rate = 0,0

max_layer_height = 0

max_print_height = 195

min_layer_height = 0.07

nozzle_diameter = 0.4

parking_pos_retraction = 92

pause_print_gcode = M601

print_host = 

printer_model = 

printer_notes = 

printer_settings_id = 

printer_technology = FFF

printer_variant = 

printer_vendor = 

printhost_apikey = 

printhost_cafile = 

remaining_times = 1

retract_before_travel = 2

retract_before_wipe = 0%

retract_layer_change = 0

retract_length = 2

retract_length_toolchange = 10

retract_lift = 0

retract_lift_above = 0

retract_lift_below = 0

retract_restart_extra = 0

retract_restart_extra_toolchange = 0

retract_speed = 40

silent_mode = 1

single_extruder_multi_material = 0

start_gcode = ;G28 ; home all axes\n;G1 Z5 F5000 ; lift nozzle\nG28   ;Home\nM298 ;Move Nozzles on Bed plate\nG0 F9000 Z3.00 ;Z-leveling\nM206 X0.0 Y0.0 Z-0.15 ;Offset z direction\n\nG1 F2400 E-6.000000 ;Retraction to prepare for printing

template_custom_gcode = 

thumbnails = 

toolchange_gcode = 

use_firmware_retraction = 0

use_relative_e_distances = 0

use_volumetric_e = 0

variable_layer_height = 1

wipe = 0

z_offset = 0

[presets]

print = 3DWOX1

sla_print = 

sla_material = 

printer = 3DWOX1

filament = 3DWOX1

Although the estimated remaining time displays as 0h 0m during printing the Prusa Slicer is consistently produces gcode that results is dimensionally accurate complete prints.

In this long print, the object rests on a 2mm chamfered corner, some supports around and a 6mm brim around. There is much less warping than if the object was printed with the flat bottom edge on the bed.