If the retraction distance is too high and the retraction speed is too slow, the nozzle won't be primed with enough materialwhen the next layer starts, resulting in gaps. Enclosure -Highly recommended for best results. Stringing / Oozing
Printing supports with a dense interface can improve the underside surface quality of your models. We recommend storing all filaments in a resealable bag with desiccant when not in use andwe recommend using a filament dry box like the PolyBox when printing. For PCwe recommend first trying the surface your 3D printer was designed to use. Ifthe printing speed is faster than the filament can reliably melt and extrude a jam may occur. This was most likely due to the ability of the printer to maintain a consistent bed temperature of 135C. 1. Cracking
on three popular printers. If the nozzle temperature is too high, it is possible for raft to permanently fuse to the model, requiring pliers or a chisel to remove. Polycarbonate will also 3D print with less stress and thus better strength when printing with an enclosure and or a heated chamber. This is especially true with Polycarbonate since a mediocre first layer will result in a print failure due to warping and the print peeling from the bed surface. 
This process typicallyoccurs over a period of months however in high humidity environments (ie. Filament manufacturer Polymakerassisted with the rise of PC 3D printing by formulating the first optimized PC material for both desktop and industrial 3D printing, their filament PolyLite PC is less demanding and printsat250Cinstead ofrequiring a300C nozzle temperature and heated chamber. Buy PolyLite PC. Changing from a higher temperature material:
To find a suitable desktop 3D printer to work with MatterHackers Polycarbonate, several printers were tested to include the Ultimaker 3, Raise3D N2 and the Lulzbot TAZ 6. Once the Polycarbonate filament is flowing nicely and all remaining traces of the previous filament is no longer deposing, increase the hot end temperature to 290C. 
For optimal results, it is recommended that you pre-heat the buildplate to 90C at least 10minutes before 3D printing PC. If your extruder temperature is too low during printing, the PCfilamentwill notflow and will have difficulty extruding. A similar annealing process can be applied with some 3D printing materials and in the case of polycarbonate, will release internal stressmaximizingmechanical performance. If your extruder temperature or flow rate is too low during printing, the PC filament won't extrude properly, leaving gaps within the model. We recommend printing with the cooling fan set to a LOW settingto achieve the best underside surface quality. Some printers on the market print on flexible build plates. Just like sandpaper, there are many different grades of tumbling grit. Printing with a secondary material will require a printer capable of multi-material / dual extrusion printing. So how can we prevent warping and achieve near-zero warpingwhen printing PC. PC doesn't have any specific feeding path requirements. Warp Free PolyCarbonate (PC) 3D printing is here! Poor surface quality
When printing PC, supports can either be printed in PC or with a second dedicated supportmaterial. *Use extreme caution when printing with Cyanoacrylate since the heated liquid compound produces fumes that are an irritant to both eyes and lungs. 
Decreasing the printing speed may help prevent this issue in the future. If the nozzle is blocked with PCone of the most successful solutions is to increase the nozzle temperature and manually feed more PCthrough the extruder / hot end. Based on the quality of the print we suggest adjusting 5C at a time. On other surfaces, e.g. This issue is known as heat creep, click here to learn more about this issue. Temporarily turning off retraction settings is one way to see if retraction is causing gaps in the model. Changing from a lower temperature material:
If your filament has absorbed moisture it can be dried in a convection oven. Annealing is a process commonly used in metallurgy to heat the material and remove internal stress and toughen parts. PolyMax PC also offers a further improved printing experience, printing with less warping and with easier to remove support material. This article has been written to provide both printing and troubleshooting tips along with tips for post-printing processes like painting andsupport removal. Printing with the right bed surface is very important when printing PC. Support Troubleshooting -If supports are fusing to the model, try decreasing the printing temperature by -5C adjustments or increase the distance between the model and supports. Below is a list of the test results while printing with. If your extruder is not water cooled we recommend heating the chamber to40-60C to prevent heat creep. If the bed temperature is too high, it is possible for the raft to permanently fuse to the model. What constitutes too long depends on the relative humidity in the air, but when it comes to 3D printer filament, it is best to err on the side of making the filament too dry rather than allowing it to be a little wet. After opening a spool and when not in use, make sure to keep Polycarbonate filament in vacuum-sealed or resealable storage bags with desiccant packs. Some are actually co-polymers to make PC easier to print, but in doing so essentially tones down the capabilities of pure PC. Adjusting the first layer height and the printing speed can impact how models will adhere to the raft. Low grade grit can be used to make coarse surfaces while higher grade grit can make very smooth and fine surfaces. Tests were run to determine the optimal bed temperature for layer adherence and curing. Next, be sure to keep all your print speeds throughout the part at or below 20mm per second. Effects of Moisture:
We recommend sanding to eliminate the layer lines from PC3D prints however parts can also be post-processed with techniques like tumbling. To prevent this issue itis important to print with the bed leveled and the correct nozzle height. Flexible Build Platform
LOW fan settingsmay be applied to improve overhang quality, especiallywhen printing with a heated chamber. Annealing polycarbonate releases the internal stress properly, maintaining the materials true strength and toughness. When the filament passes through the hot end the moisture rapidly expands creating bubbles in between layers, poor layer adhesion, inconsistent extrusion due to material expansion and thus poor surface quality. Polycarbonate filament that isn't sufficiently dry before printing or manufactured poorly will not print properly and can cause defects and issues that will waste your time. As the filament is extruded, the moisture will expandand rupturein the filament creating a rough and inconsistent extrusion. As far as printing temperatures go, you need a 3D printer with a hot end that can reach and maintain a minimum of 290C. 
If the manufacturer recommends 250C - 270C, printing at 260C is a good starting point. Heated Chamber-Beneficial
Note: When it comes to 3D printing Polycarbonate,set up and settings may vary depending on the grade of PC. You can try making slight adjustments to the. It is important to ensure your. If the material is printed without a heated environmentthe material will print withresidual stress. We have a broad range of support options including Telephone Support, Shipping to: New South Wales (NSW) - Australian Capital Territory (ACT) - South Australia (SA) - Western Australia (WA) -Victoria (Vic) - Queensland (QLD) - Northern Territory (NT) - Tasmania (TAS) - New Zealand (NZ). Stop extruding the PCfilament after the previous material has been completely purged and cleaned out, lower the temperature to suit your PC filament and extrude the PC plastic for a few more seconds. Advanced slicer settings like coasting can be turned on to effectively reduce stringing. What is required is a good printer that heats to and holds high hot end and bed temperatures, a good print surface, the right adhesive and the ability to partition and/or control the ambient temperature around the printer. Finally, remember to disable the filament cooling fan(s) during printing. Most 3D printing slicers(software) have a pre-configured PCor ABSprofile. 
Besides the fact that high temperatures are necessary, Polycarbonate just doesnt stick to anything. When printing at finer layer heights (0.1 and 0.05mm) the correct nozzle height is even more important. 
If your nozzle is partially blocked the filament will have difficulty extruding. Preventing Moisture Absorption:
As far as printing temperatures go, you need a 3D printer with a, How To Build An Enclosure For Your 3D Printer, To find a suitable desktop 3D printer to work with, , several printers were tested to include the, . A brim is a thin layer of material surrounding the print that can be addedhelp improve bed adhesion. Filament cooling fans adversely affect curing of the print and should not be used. If you hear a clicking or clunking sound coming from the extruder, this is a good sign that the filament is jammed or will be if ignored. If you are printing with a heated chamber and encounter heat creep related jamming we recommend firstlowering the chamber temperature. The water will assist to keep the sand paper clean and will dissipate heat from the sanding. We recommend printing your parts with at least 3 perimeters/shells or a minimum wall thickness of 1.2mm if you plan on sanding. If the nozzle temperature is too hot, you may experience wisps / stringing on the surface of the print, difficult to remove and fused support material , sagging and poor surface quality on overhangs and a noticeable smell during printing. If there are gaps in the top surface of your 3D print this is commonly referred to as pitting. in this case it is important to prevent the part from warping. The pressure can be evened through the foam block to create a smoother surface. Please wear a face mask when sanding to prevent breathing any dust or particles. Printing with the wrong retraction settings can negatively impact the quality of a 3D print. Unsuitable combinations of solvents in the paint system can attack the material and, depending on the stress condition of the parts, may initiate stress cracking. If the filament is softening in the hot end, the extruder will 'chew out' the filament, causing a nozzle jam. Slowing down your printing speeds can help to minimize vibration, ensure consistent extrusionand improve printing quality. PolyMax PC is a nano-reinforced and optimized polycarbonate material exhibiting vastly superior impact resistance when compared with other grades of polycarbonate. Rigid Build Platform
From the test results, one can see that printing Polycarbonate well takes a good adhesive, a good print surface and a bed temperature of at least 135C. 
Stop extruding the PCfilament after the previous material has been completely purged and cleaned out. How Do I Print With Polycarbonate Filament? It is recommended that an overall printing speed, including infill, should not exceed 20mm per second. Reducing the infil percentage or changing the support pattern can help improve support removal. As polycarbonate is a considerably tough material, with assistance and a high nozzle temperature you can generally purge and remove the clogged plastic. 
Without these adhesives, the Polycarbonate print will warp and easily pull off the heated bed. By controlling the travel and flow behavior in the slicing software we can minimize and prevent oozing and stringing. We recommend following our tips in relation to, Poor layer adhesion can also be caused when printing with PCthat has beenspoiled with moisture. If the retraction speed is too high, the feeding gear may grind the filament, causing a. A high temperature heated bed is necessary for printing with Polycarbonate, Figure 2: Layer separation at the surface, Figure 12: Layer separation and burn residue. Feel free to reach out with any specific questions about your Polycarbonate 3D printing experience.Happy Printing! If you are printing on glass (without Magigoo PC), please always remove the part when the glass bed is HOT. [1] -If you are not using Magigoo (an adhesive which self-releases), we highly recommend removing your models immediately after printing when printing directly to glass. PC Filament Introduction
Polymaker Qualifies New Industrial PC Materials for MakerBot LABS. It is important to load the PCat this higher temperature so the previous material can be pushed out. As mentioned, Polycarbonate is hard to print but not impossible. For this reason, Polycarbonate should be stored in a cool, dry place and dried if exposed to humidity for too long. 
If the printer is currently loaded with PCor a similar material,unload that material at 250-300C and extrude your Pcfilament at the same temperature. Pitting can be related to temperature or moisture however generally occurswhenthe infil is to low to support the top layers of the 3D print. One of the best engineering plastics available for 3D Printing, PC was previously considered a difficult material to print. These printers were out of the box and not modified in any way to ascertain true performance while printing Polycarbonate. These test prints were completed with non-modified stock printers, so the maximum bed temperature achieved was 135C. Sarolea electric superbike, 3D printing from prototyping to production. Once it's all said and done though, successfully printing Polycarbonate filament can enable you to print some stellar and almost indestructible RC cars, drones, or anything else you can imagine. store the PCcorrectly and prevent this issue from occurring. This may make the supports challenging to remove, but it helps to mitigate layer separation throughout the print. ThePolyBoxis a spool holder / dry boxthat stores filamentin their optimal environment whileprinting. When printing higher temperature amorphous materials like PC, some users can have difficulty preventing warping, firstly lets look at why PCmaterials can warp. Click here if you are having issues with wisps and stringing. Next, adjust the temperature on the hot end to match the new filaments printing temperature. Some 3D printers are equipped with HEPA/ carbon filters which can help to minimize the smell when printing PC plastics. 
If you have had success 3D printing PCbefore then PCshould perform similarly. Cleaning an PCNozzle Blockage
Some printers are designed so the platform can be removed from the bed while other printers the build platform may be fixed inside the printer. 6top layers with a 0.2mm layer height will result in a 1.2mm top surface thickness, the same number of top layers at 0.1mm layer height will only result in a 0.6mm top surface thickness. 
When changing between bed surfacesit is important to adjust the nozzle height again to compensate for the added thickness of the bed surface. An easy way to test for moisture content in a spool of filament is to extrude the filament, ifyou heara distinct popping sound your filament has likely absorbed moisture. Adjustingretraction behavior or the extruder gear tension can solve this issue. Even with a bed temperature of 110C, the printed part will separate or crack between the layers of deposition and will easily break apart by hand. Your nozzle height must be set correctly. The ideal grit to choose will depend on what surface quality you require. Joining, Trouble Shooting
Without a good first layer you will likely need to reprint the item, so its imperative that you know what it takes to start a print off right so it can build to completion. When using soluble supports we recommend having no gap (z distance) between the model and supports. If the filament is of poor quality is oval shaped ormanufactured with an inconsistent diameter, this can cause the filament to jam in the extruder. If the nozzle temperature isn't hot enough, you may experience compromised mechanical properties due to the poor layer adhesion, under-extrusion (uneven / rough surface quality) and if the filament is not melting fast enough; nozzle blockages. Buy PC Filaments, PolyLite PCIntroduction
Preferably the bed temperature should be between 145C - 150C. If you attempt to print Polycarbonate on a printer that cannot heat the bed to at least 135C, you are most likely wasting your time. In fact, the best surface to use when printing with Polycarbonate is Polycarbonate. To anneal polycarbonate, place the part in a preheated oven for one to two hours at 100C. We test printed at 290C. 
Annealing*
If the nozzle height is set too close tothe bed, the filament will have difficulty feeding through the nozzle eventually causing a filament jam. Changingfrom a PCmaterial
Too much friction on the filament feeding path can result in under extrusion. The raft can be removed once the print has completed. A raftis recommended for the best results. Printing with 12 top layers with a 0.1mm layer height will achieve the 1.2mm top surface thickness. Enclosure*
Polycarbonate (PC)offers excellent heat resistance and tensile strengthfor real world applications. Difficult to remove supports / raft, Filament Links
Some users will simply dry their filament before use howeverexcessivedrying will degrade the filament. Like other grades of polycarbonate, PolyMax PC offers moderate chemical resistance and excellent temperature resistance, softening at 113C (Glass Transition and Vicat temperature). Pre-heating*
As the filament is extruded through the small diameter of the nozzle, the polymer chain of the filament is stretched and will want to return back to its normal state, much like a stretchedelastic band will go back to its position when it is released. If the filament is under-extruding during printingthere will be inconsistencies and gaps between the layer, compromising mechanical strength and layer adhesion. Click here if you are having issues removing prints from the build platform. 
If the poor qualityis related to retraction, printing with a lower retraction distance,faster retraction speed or turning off coasting may solve under extrusion when printing with retraction. Preheating will help to ensure the bed is evenly heated and increase the ambient temperature to minimize risk of warping. As such, this material needs high temperatures in order to extrude and have proper layer adhesion. Causes and steps to improve print removal experience. PC exhibits a moderate chemical resistance and excellent temperature resistance, with some grades softening between 145150 C (Glass Transition and Vicat temperature). Removing Moisture:
To eliminate all possibilities of moisture impacting your 3D prints, you muststore and print your PCmaterials in their optimum environment (below 20% humidity) to prevent moisture absorption. Causes and steps to improve poor layer adhesion. Minimum Extruder Temperature - 250C (10C) is required(Correct temperature willvary on your printer)
Printing with alower nozzle temperature can also improve overhang surface quality. PolymakersPolyLite PC and PolyMax PC filaments for example have been optimized to print at lower printing temperatures (250C). If models are fusing to the sheetsyou can increase your nozzle gap or add a layer of Magigoo PC orglue to act as an interface. It is therefore recommended to contact the paint manufacturers who can supply suitable paint systems especially for PC. Or which filament will suit your application? This can cause many problems including the filament chewing out instead ofgripping and feeding through the hot end. Printing on the lower end of the materialsextrusion temperature can also help reduce heat creepin some cases. With that in mind, it is usually better to print with a raft or with a large brim that comes into contact with the edge of the model surface. Part Cooling Fan -OFF
Recommended - Straight on glass bedwith a thin layer ofMagigoo PCor glue. Warping
PC typically prints with an attractive satin surface finish. Causes and Steps to PreventNozzle Blockage and filament jams. Removing a print after the bed has cooled may cause the glass to break as the print canshrink more rapidly than the glass plate. 
To reduce resistance on the filament you can move the spool holder closer to the 3D printer and checkthe curve of the filament guide tube is not too tight. Follow these helpful steps to start successfully printing with this extremely tough, professional grade material. When printing PCwith multi-material capabilities we recommend usingPolyDissolve S2. PC Supports - With single extrusion 3D printers themodel and supports are printed with the same material. Bed Temperature*
Once your 3D print hascompleted, it can be removed from the build plate. When not in use PC should be stored away from sunlight and in a resealable bag with desiccant. The one that produced the best prints was the Lulzbot TAZ 6. A part which isnt annealed will slowly release any internal stress in the form of micro-cracking, which can compromise up to 50% of the parts strength. If the printer is currently loaded with a higher temperature material, unload that material at its recommended printing temperature, and then load and extrude your PCfilament at that same higher temperature. If the part is warping or lifting off the bed, the part will be pushing against the nozzle limiting extrusion and material flow. The ideal gap between the nozzle and bed is typically adistance of 0.1mm, this is the thickness of two pieces of paper. It is important your heated bed isnt set above the materials glass transition temperature. 
Once mastered Polycarbonate yields the strongest and most durable desktop 3D printed parts from filament that exist today, but only through continual print iterations to maximize the results. Rafts/ Brims
With a compatible combination theperforation on the board will grip the model during printing to help prevent lifting or warping. Printing with a dry box is generally not a critical requirementto print PC(in most cases) however a dry box can be beneficial and ensure consistentprinting quality and mechanical resultsthroughout the spool. Supports, Post Printing
Warping is caused by internal stress in the 3Dprinted part; there is one cause for internal stress when printing amorphous materials. Often times an enclosure is necessary to keep the ambient heat around the printer stable (please reference How To Build An Enclosure For Your 3D Printer). [3] -This method is generally successfulhowever will rely on compatibility between the PCand material of the perforated board. Check out our in-depth article on how to Beat Moisture Before It Kills Your 3D Printing Filament and how you can successfully dry and maintain your Polycarbonate filament. Click here for trouble shooting tips regarding blocked nozzles. Heated Bed -Required, 90 - 105C. Filament Storage, Printer Settings
The best method to remove your PC3D prints will depend on your build platform with some of these methods specific to removing PCprints. Spooling
A plastic cutting board or a sheet of garolite will do. If there is too much friction on the filament, the extruder may have difficulties feeding the plastic. By increasing the retraction length or retraction speedin your slicer settings, the extruder will withdraw a short distance filament from the nozzle, helping to preventoozing when the extruder travels between points.
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