<p>The object on the right is a basic C channel, the outer surface should be smooth but the first ~5 mm of filament is missing after every layer change. In this example, the missing filament is reasonably consistent and extreme. The object on the left (from the same print) has a seam where the filament is also missing but it was not a layer change so it is only missing 1-2 mm.</p>
<p><a href="https://i.stack.imgur.com/mepw9.jpg" rel="nofollow noreferrer"><img src="https://i.stack.imgur.com/mepw9.jpg" alt="enter image description here" /></a></p>
<p>But when printing a benchy the gap is not as large and has different lengths. The other side of the Benchy looks great, this side has all of the seams on it.</p>
<p><a href="https://i.stack.imgur.com/5UIwH.jpg" rel="nofollow noreferrer"><img src="https://i.stack.imgur.com/5UIwH.jpg" alt="enter image description here" /></a></p>
<p>Details</p>
<ul>
<li>Anet A6 direct drive</li>
<li>Marlin firmware with the latest Octoprint</li>
<li>Heated enclosure, glass bed @ 60 °C</li>
<li>eSun PLA, have used many cheaper brands all with the same issue</li>
<li>Printing at 210 °C but have tested 180-220 °C</li>
</ul>
<p>When printing an army of Benchys, I thought this was a retraction issue and test all sorts of settings with small increments but did not fix the issue. It was after printing this C channel that the issue was more clearly highlighted.</p>
<p>Things that I have attempted to resolve this</p>
<ul>
<li>Geomerty calerbration</li>
<li>Extruder calerbration</li>
<li>Filament temperature range tests</li>
<li>Retraction distance and speed towers</li>
<li>Retraction distance and temperature towers</li>
<li>Disabling retraction (worth a short) - Disabling retraction during only Z hop (did nothing)</li>
<li>Different version of Cura</li>
<li>Different filament brands</li>
</ul>
<p>Can not seem to figure out what the issue here is and have run out of ideas on what to do next.</p>


[{'answer_id': 19554, 'author': 'fred_dot_u', 'author_id': 854, 'author_profile': 'https://3dprinting.stackexchange.com/users/854', 'pm_score': 2, 'selected': False, 'text': '<p><a href="https://www.instructables.com/Copper-Electroforming-on-3d-Printed-PLAABS-Objects/" rel="nofollow noreferrer">Electroforming</a> is the process of applying a conductive paint to a non-conductive surface. Once dry, the object is subjected to a process similar to electroplating, in that molecules of a conductive, more durable metal are bonded to the conductive paint, which is bonded to the 3D printed part.</p>\n<p>Typical metals would be nickel, which is quite conductive, as well as copper, known for conductivity. One could be somewhat absurd and perform the same process with silver and gold. The absurdity is related to the expense of those materials.</p>\n<p>The link covers using copper, but I believe that nickel would be more durable.</p>\n<p>Your joint selection is more related to the strength of the design and contact surface area and may be better suited for a more detailed separate question.</p>\n<p><a href="https://i.stack.imgur.com/ypefi.png" rel="nofollow noreferrer"><img src="https://i.stack.imgur.com/ypefi.png" alt="electroformed 3d printed calibration cube" /></a>\nAs usual, image from linked site.</p>\n'}, {'answer_id': 19557, 'author': 'Eduard Sukharev', 'author_id': 10944, 'author_profile': 'https://3dprinting.stackexchange.com/users/10944', 'pm_score': 1, 'selected': False, 'text': '<p>For your task you basically have several options:</p>\n<ol>\n<li><strong>Electroforming</strong> (see @fred_dot_u answer). Pros: high electrical conductivity due to actual metal layer; very low friction between polished metal layers. Cons: the process is quite dirty and requires additional materials and processing, plus some skill to produce results of appropriate quality.</li>\n<li><strong>Conductive filament</strong> (e.h. <a href="https://www.makerbot.com/3d-printers/materials/method-pla/" rel="nofollow noreferrer">PLA from Makerbot</a>). Pros: direct printing of any form. Cons: high price, probably tricky to print with, high current resistance.</li>\n<li><strong>Sliding electrical connections</strong> (e.g. as in brushed motors or magnetic USB charging cables). Pros: when properly executed will be very durable and probably could even reuse parts from existing markets (brushed motors use this trick for very long time). Cons: requires additional engineering and redesign of your existing parts.</li>\n<li><strong>Wireless connection</strong> (e.g. parts use radio/Bluetooth/WiFi for communicating). Pros: independent functionality of each \'limb\'. Cons: independent power sources required for each limb; complex communication means.</li>\n<li><strong>Optical signalling</strong>. Pros: no electrical connections; depending on your use-case might fall in-between <em>wireless connection</em> (without the need of additional power source) and <em>sliding/magnetic connections</em>. Cons: requires skills and tools to work with fiberoptics, which is totally different story.</li>\n</ol>\n<p>Depending on your resources, requirements, skills and time you would chose one of above. You may also find some alternative solutions from engineering world.</p>\n'}]
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