Avoiding Common Operator Errors for Successful Resin 3D Printing

by Christopher Lannon July 16, 2023

With resin 3D printing, a single operator mistake can mean the difference between a smooth print and a failed print. From the initial setup to post-processing, resin printing requires careful attention to detail from the operator. Even small oversights in the process can lead to uncured prints, resin spills, model errors, and more.

In this detailed guide, we’ll go over some of the most common operator errors and how to avoid them through proper resin 3D printer operation and technique. Mastering these areas will help you achieve successful prints each time.

Poor Build Plate Leveling

One of the most critical steps that is easy to mess up is build plate leveling and tramming. If the build plate isn’t precisely leveled, prints will not adhere properly during the printing process. Resin can leak under the build plate leading to curing issues.

The build plate must be accurately trammed and calibrated to the resin vat. This establishes the precise zero point for the Z-axis. Even being off by a small amount can cause problems.

To properly level and tram the build plate:

Carefully follow all leveling and tramming steps outlined in your printer's manual. Don't skip any steps.
Use the proper leveling tools like the provided paper or tramming block with the specified thickness. Incorrect tools will throw off your leveling.
Check the tightness of the ball screws and mechanisms that secure and level the build plate. Any looseness can cause warping.
Re-level and tram the build plate any time the printer is moved or serviced. Vibrations can knock the plate out of calibration.

Take your time with the tramming and leveling process. Rushing through this critical step leads to headaches later.

Poor Print Orientation and Supports

The orientation and placement of supports when preparing models is also critical for avoiding print failures and achieving high detail on your prints. Models oriented incorrectly or with improperly generated supports will fail to print properly.

To optimize print orientation and supports:

Orient models strategically to minimize the required number of supports and avoid visible support marks on surfaces.
Angle models to allow uncured resin to drain freely back into the vat. Trapped resin causes defects.
Place dense supports under all overhangs, islands, and projections to prevent warping and deformation. Skimping on supports causes failures.
Use the native slicer tools to auto-generate supports for optimized placement and density. Manually placing supports is tedious and error-prone.

Take advantage of orientation strategies and auto-generated supports to reduce operator errors and ensure print success.

Incorrect Exposure Settings

Dialing in the optimal exposure times and settings is crucial for achieving detailed, high-quality resin prints. The default settings pre-configured in your printer profile rarely give the best results for each resin.

To optimize your print exposure settings:

Refer to the resin manufacturer's recommendations for base curing times and settings for the specific resin. These serve as a good starting point.
Print exposure calibration tests to dial in the optimal bottom layer count, bottom layer exposure time, normal layer exposure time, and rest time between layers.
Adjust the normal layer and bottom layer exposure times incrementally based on calibration print results. It takes fine tuning to get it right.
Check each print closely and make additional exposure adjustments as needed for improved accuracy and quality. It's an iterative process.

Don't settle for mediocre default settings. Take the time to calibrate your printer profile's exposure settings properly.

Resin Pouring Mistakes

Careless and messy resin filling causes toxic spills, trapped bubbles in the resin vat, and contamination. Slow, deliberate resin pouring technique prevents these issues.

Follow these best practices for proper resin pouring:

Always wear PPE including nitrile gloves and eye protection when pouring resin to prevent skin contact. Resin is toxic before curing.
Work over a disposable surface like cardboard to catch any spills or drips when filling the resin vat.
Pour resin slowly and deliberately into the vat to prevent splashing and introduction of bubbles. Go slow.
Stop pouring precisely at the fill lines in the vat. Overfilling leads to leaks and waste. Underfilling causes print issues.
Wipe the resin bottle with a paper towel after pouring to prevent toxic resin drips.
Inspect the vat to ensure no debris or film is present before pouring in fresh resin.

Careful resin handling prevents failures and safety issues. Take your time and don't rush this step.

Slicer Software Errors

Model errors, faulty auto-generated supports, or corrupted print files produced by third-party slicers can easily lead to resin print failures if not properly inspected before printing.

To catch and avoid slicing errors:

Thoroughly review and inspect 3D models for any defects or problems before loading into your slicer software.
Only use recommended and properly configured slicer software geared for resin 3D printing. Avoid cheap slicers.
Carefully check the sliced file in your slicer before printing. Look for missing supports or anomalies.
Be prepared to re-slice the model in the slicer software if any defects are found in the prepared print file.
When using a thumb drive to transfer the print file, check for potential file errors or corruption before printing.

Don't blindly trust third-party slicer software. Verify the sliced file integrity before committing to a print.

Mishandling Uncured Prints

Uncured resin coming straight out of the printer is toxic and poses hazards if handled incorrectly. Always use proper PPE and follow post-curing best practices.

Safe and proper resin print handling technique:

Wear nitrile gloves at all times when removing fresh prints from the printer before washing and curing. Avoid skin contact.
Thoroughly rinse prints under alcohol or in a wash station to remove all uncured resin before curing.
Closely follow resin manufacturer guidelines for post-print UV curing times to fully harden prints.
Allow prints to fully cure in the curing station before handling them with bare hands to avoid toxicity.
Store uncured wet prints securely in a lidded hazardous waste container to prevent leaks or exposure.

Never cut corners when handling uncured resin prints. Safety comes first.

Operator Error Troubleshooting FAQ

Still having issues with operator errors? Here are answers to some common troubleshooting questions:

How can I get a perfectly leveled build plate every time?

Carefully follow the provided leveling procedure in your printer manual using the specified tools. Take your time with each step. Re-level anytime the printer is disturbed.

Why do my supports keep failing and prints de-laminating during printing?

Increase support density for overhangs, optimize orientation to minimize supports needed, and place supports strategically based on resin printer support rules.

How do I dial in the right exposure times for my resin?

Refer to manufacturer recommendations, run exposure calibration tests, and incrementally adjust normal and bottom layer times based on print test results. It takes fine tuning.

What is causing bubbles to appear in my resin prints?

Pour resin slowly into the vat, degas resin before use, raise models very slowly, and use proper supports. All reduce trapped bubbles.

How can I catch print file errors before starting a print and wasting resin?

Thoroughly inspect models before slicing, check the sliced file for issues, use recommended slicers, and verify file transfer to the printer.

Is it safe for me to handle prints before washing and curing?

Never handle uncured wet prints without gloves. Always wash, post-cure, and allow full curing before touching. Store properly.

Mastering resin print preparation, slicer setup, exposure settings, resin handling, and post-processing will help you eliminate operator errors. Pay close attention to detail throughout the full printing workflow for consistent success. Let me know if you have any other resin printing questions!