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Holes and Gaps in Floor Corners

When building a 3D-printed part, each layer on top of the previous layer. All previous layers together form the foundation of the current layer. The foundation should be strong enough. Otherwise you will start to see holes and gaps between the layers. Typically when you are printing a smaller feature on top of a bigger feature, such as a small cube on top of a bigger cube, the smaller cube is sitting on the top solid layers of the bigger cube, under which is the partially hollow infill. If the partially hollow infill and the solid layers on top it is not strong enough to hold the small cube, then you will see holes and gaps between layers.

Check the following things to solve the problem.

  • Not enough perimeters

Adding more outline perimeters to your part will greatly improve the strength of the foundation. Because the interior of your part is typically partially hollow, the thickness of the perimeter walls has a significant effect. To adjust this setting, you can adjust the shell thickness after choosing “Next” in Print page. For example, if you were previously printing with two perimeters, which equals to 0.8mm shell thickness, try the same print with four perimeters, which equals to 1.6mm shell thickness to see if the gaps disappear.

  • Not enough top solid layers

As mentioned above, not having enough top solid layers will end up with a thin ceiling which will not be able to adequately support the structures that are printed on top of them. This setting can be adjusted by clicking “Advance” and selecting the Infill tab. If you were previously using only 5 top solid layers, try the same print with 10 top solid layers to see if the foundation is improved.

  • Infill percentage is too low

The other setting you should check is the infill percentage used for your print, under the Print Settings called Fill Density. The top solid layers will be built on top of the infill, so it is important that there is enough infill to support these layers. For example, if you were previously using an infill percentage of 15%, try increasing that value to 20% to see if the print quality improves.