3D Printing Errors: Practical Solutions
You leave a print running overnight, and in the morning, there's just a tangled nest of filament on the print bed – that happened to us at the beginning too. Or the prototype looks good at first glance, but has fine stringing, warped corners, or visible layer shifts. In our workshop at 33d.ch, we see precisely these kinds of cases constantly, with our own tests as well as with parts from customers. It's annoying, costs time, and in the worst case, leads to missing an important delivery deadline.
So that you don't have to start from scratch every time, we've compiled the most common 3D printing errors, summarized typical causes, and added practical settings that have proven themselves in our daily work. The goal: a handy diagnostic tool that allows you to achieve consistently better prints – whether you're working at home, in a makerspace, or in an SME.
Quelle: Own Presentation
Common Print Errors
In FDM 3D printing, a plastic filament is melted and built up layer by layer. Even small deviations in temperature, extrusion rate, cooling, or mechanics lead to typical error patterns. We see many of these repeatedly – from inexpensive entry-level devices to professional systems.
Quelle: techkrams.de
Common 3D printing errors at a glance: layer shift, blobs, and stringing.
Stringing
Stringing refers to those fine "spiderwebs" between two areas of the component, usually occurring during travel moves without actual extrusion. Often, a too-high nozzle temperature or poorly tuned retraction is the cause, allowing filament to ooze out even when the extruder should have stopped (All3DP, Creality).
This is why, especially with new filaments, we at 33d.ch first perform a small stringing test with graduated temperatures and retraction values. It only takes a few minutes but saves many frustrating hours with "spiderweb parts."
Warping
Warping occurs due to uneven cooling: the lower layers shrink differently than the upper ones, causing corners to lift off the print bed and the component to visibly bend upwards (snapmaker.com). This is particularly critical for large, flat parts and materials like ABS or Nylon, which shrink significantly more than PLA (Qidi Tech Online Store).
Quelle: techkrams.de
Warping: The corners of the 3D print detach from the build plate.
When we print large covers or functional prototypes for a mechanical engineering client, we always factor in warping: activate brim, use an enclosed build space, and if necessary, split the part into several segments that are later screwed or glued together.
Poor First Layers
If the first layer doesn't adhere properly, a failed print is often pre-programmed. Components detach, corners curl up, or the first layer is so heavily squished that it looks bad and is difficult to remove (Prusa Wissensdatenbank). Common causes are incorrect nozzle-to-bed distance, a dirty surface, excessive print speed, or inappropriate temperatures (simplify3d.com).
In our workshop, we don't start any important job without a quick first-layer check: a small test square, clean the bed, fine-tune the Z-offset – only when that's right does the "real" print begin.
Underextrusion (Gaps, Holes)
Underextrusion manifests as gaps between lines, incomplete perimeters, weak layers, or translucent infill structures (simplify3d.com). Infill is, simply put, the internal structure of the part – a grid between the outer shells; if you can see this too clearly, the material flow is usually incorrect. The cause can be in the slicer (too low flow, temperature, too high speed) or in the hardware (clogged nozzle, worn drive gear) (All3DP).
Layer Shift
Layer shifts are sudden horizontal displacements in the component, often occurring at a certain height or after a small collision of the nozzle with the part (Prusa Wissensdatenbank). This usually indicates a mechanical problem: loose belts, insufficient motor currents, blocked guides, or strong vibrations at high speeds (Qidi Tech Online Store).
Layer Separation / Delamination (Cracks)
Layer separation appears as horizontal cracks or peeling layers, especially with taller components and materials with high shrinkage like ABS (simplify3d.com). Often, the extrusion temperature is too low, the layer height is too large relative to the nozzle diameter, or the part cooling is set too high (All3DP).
Elephant's Foot
Elephant's foot describes a wider, slightly swelled first layer that extends beyond the component's contour (Polymaker Wiki). Often, the bed temperature is too high or the Z-offset of the first layer is too small, causing the filament to be pressed too heavily into the bed (Kingroon 3D).
Zits and Blobs
Zits and blobs are small bumps or thickenings, usually at the points where a perimeter begins or ends (simplify3d.com). The cause is pressure in the hotend when movement stops, overextrusion, an unsuitable seam position, or unfavorable retraction and coasting settings (Wevolver).
Ghosting / Ringing (Ripples)
Ghosting or ringing are wavy shadow lines behind sharp edges, as if the contour had "afterimages" on the surface (All3DP). These ripples are caused by vibrations in the printer frame and axes, often at too high speeds, loose belts, or a wobbly base (snapmaker.com).
Clogged Nozzles
Clogs manifest as a sudden loss of material flow, severe underextrusion, or completely empty lines, even though the printer continues to move (Prusa Wissensdatenbank). Causes often include material residue, burnt plastic, dust, incorrect temperature changes, or filament changes without sufficient purging (Prusa Wissensdatenbank).
Quick Overview: Errors & First Steps
| Error Pattern | Typical Main Cause | First Sensible Step |
|---|---|---|
| Stringing | Too high temperature, unsuitable retraction | Lower temperature in 5°C increments, print retraction test |
| Warping / Detaching Corners | Significant temperature differences, poor adhesion | Activate brim, clean bed, close or enclose build space |
| Poor First Layer | Incorrect Z-offset, dirty bed | First-layer test print, degrease bed, readjust Z-distance |
| Underextrusion | Insufficient material flow or partially clogged nozzle | Check flow and temperature, clean nozzle |
| Layer Shift | Mechanical issues / belts / too high speed | Check belts, reduce print speed and acceleration |
| Layer Separation | Extrusion too cold or part cooling too strong | Increase temperature, reduce fan speed, stabilize build space |
| Clogged Nozzle | Material residue, dust, incorrect temperature changes | Perform cold pull, clean filament path |
Troubleshooting & Slicer Settings
Good troubleshooting guides show how the same problems recur on many printers and can usually be managed with a few clear setting adjustments (simplify3d.com, Prusa Wissensdatenbank, All3DP). In practice, we often orient ourselves by these procedures and adapt them to our printers and materials.
A typical approach in our daily work: First, a neutral reference print with a proven profile, then we always change only one parameter block – for example, retraction, temperature, or speed – and document the result with a photo and a short note. This way, it remains traceable why a profile works well.
Stringing
A starting range of about 0.5–1 mm retraction for direct drive extruders and 4–6 mm for bowden systems, combined with moderate retraction speeds around 25–40 mm/s, has proven effective (Polymaker Wiki). Additionally, the nozzle temperature should be lowered in 5-degree increments until stringing decreases without causing underextrusion (All3DP).
Quelle: the3dprinterbee.com
Significant stringing on a 3D-printed test object.
Warping
In the slicer, helpful settings include: activating brim or raft, printing the first layer slower and slightly thicker, and keeping the bed temperature within the recommended range or slightly increasing it (simplify3d.com). An enclosed build space or a cover reduces drafts and temperature differences, which significantly mitigates warping with ABS (snapmaker.com).
Poor First Layers
A reduced first-layer speed (approx. 40–60% of normal speed), slightly increased nozzle temperature, and a slightly higher first-layer flow for more "squish" are often effective (eufyMake). An excessively small Z-offset should be avoided, as it can damage the build plate and exacerbate elephant's foot (Prusa Wissensdatenbank).
Underextrusion (Gaps, Holes)
A sensible procedure is: print a test cube, slightly increase the flow, raise the temperature in 5-degree increments, and check if the filament flows cleanly through the nozzle (simplify3d.com). If slicer adjustments don't help, the nozzle, extruder gear, and filament path should be checked and cleaned (All3DP).
Layer Shift
In the slicer, acceleration and jerk can be reduced, and the maximum print speed can be lowered to give the axes more buffer (support.bcn3d.com). Simultaneously, belt tension and the rigidity of the printer frame should be checked (All3DP).
Layer Separation / Delamination (Cracks)
In the slicer, it helps to moderately increase the nozzle temperature, significantly reduce fan speed for ABS and similar materials, and choose a relatively small layer height in proportion to the nozzle opening (simplify3d.com). An enclosed print chamber stabilizes the ambient temperature and reduces the risk of cracks (Qidi Tech Online Store).
Elephant's Foot
In the slicer, the first-layer bed temperature can be slightly lowered, the Z-offset minimally increased, and if necessary, an elephant's foot compensation activated, which slightly pulls the contour inwards at the bottom (Prusa Wissensdatenbank). For strong adhesion, working with brim or raft is preferable to excessively squishing the first layer (Polymaker Wiki).
Zits and Blobs
Slicers offer targeted options: coasting stops extrusion shortly before the end of a movement, wipe makes the nozzle brush over the surface during retraction, and a defined seam position hides the seam (CNC Kitchen). In combination with calibrated flow and retraction, visible zits can often be reduced (Wevolver).
Ghosting / Ringing (Ripples)
Technically, it helps to reduce print speed, correctly tension the belts, and place the printer on a stable, low-vibration surface (support.bcn3d.com). Many slicers also allow limiting acceleration and jerk, which dampens the dynamics of the axes (All3DP).
Clogged Nozzles
Cold pull procedures, cleaning the filament path, and consistently adhering to recommended temperature ranges have proven effective (AzureFilm). In the slicer, it helps to avoid excessively long retraction paths, as these can pull molten material into cooler areas and promote clogs (Maker Forums).
Myths & Misconceptions
Many assumptions circulate in 3D printing that, upon closer inspection, turn out to be false or misleading. A myth check helps to distinguish between effective solutions and chance.
Myth 1: 'More temperature solves almost every 3D printing error.'
Assessment: False/Misleading. While too high a temperature can mask underextrusion, it often leads to stringing, blobs, poor detail fidelity, and material degradation (All3DP, All3DP). Systematic guides warn against seeing temperature as a universal solution; often, the right combination of temperature, flow, retraction, and speed is crucial (simplify3d.com).
Myth 2: 'A well-adjusted printer no longer needs calibration.'
Assessment: False/Misleading. Depending on the filament, ambient temperature, and wear, optimal settings change, so regular calibrations of flow, retraction, and speed are recommended (teachingtechyt.github.io). Well-known calibration guides use test models and graduated parameter series to find the best combination each time (Printer.tools).
Myth 3: 'Stringing is always just a software problem; hardware doesn't matter.'
Assessment: Unclear and too broad. While incorrect retraction and temperature are primary drivers, worn PTFE tubes, wobbly extruders, or moist filament can exacerbate the problem (All3DP, AzureFilm). Many experience reports show that stringing only disappears completely after replacing the nozzle, bowden tube, or extruder, even though the slicer settings were correct (Reddit).
Myth 4: 'PLA is always harmless; safety aspects can be ignored.'
Assessment: False/Misleading. Studies show that both PLA and ABS prints release ultrafine particles and VOCs, which can irritate the respiratory tract at high concentrations (American Chemical Society, UL). Authorities and research institutions therefore recommend good ventilation or filtration solutions – even with supposedly "harmless" materials (Umweltbehörde).
Myth 5: 'Cheap filament prints just as well as branded filament.'
Assessment: Unclear, highly dependent on batch and intended use. Measurements show significant differences in diameter tolerances, moisture content, and additives, which can affect print quality and emissions (MDPI). For decorative parts, cheaper material may suffice, but for functional parts or long-term use, tested branded filaments with documented properties are often worthwhile (All3DP).
Practical Tips & Checklist
To avoid dismissing print failures as coincidence, it's helpful to specifically document the 10 most common 3D printing errors and develop a stable base configuration from them (Printer.tools). In our workshop, a small "error gallery" has proven useful: photos, short notes on cause and solution – this way, we can find similar cases much faster later on.
Procedure for Error Diagnosis
With each change, only one parameter block should be adjusted – for example, retraction, then temperature, then speed – and the results recorded with simple test models (teachingtechyt.github.io).
Mini-Checklist 'Error Diagnosis in 5 Minutes':
- Briefly stop and take a photo: What exactly does the error look like (stringing, cracks, shift, holes)?
- Check first layer: Does it adhere cleanly, is the Z-offset correct, is the bed clean and level (Prusa Wissensdatenbank)?
- Check filament: Is it dry, moving freely, and without kinks; does the nozzle look clean or slightly clogged (All3DP)?
- Compare slicer profile: Does the temperature match the material, are flow, retraction, first-layer settings, and speeds within the usual range (simplify3d.com)?
- Conduct a test with a known good model (e.g., calibration cube, Benchy) to rule out model errors and verify the change (Prusa Wissensdatenbank).
For further research, a mix of manufacturer guides, independent technical blogs, and active community threads is worthwhile, allowing you to see both structured instructions and real-world edge cases (All3DP, AzureFilm).
Quelle: YouTube
Background & Research
Research and technical documentation offer important insights into the causes and solutions of 3D printing errors, as well as safety aspects.
Technology and Slicer Profiles
Structured calibration (temperature towers, retraction and flow tests) drastically reduces common errors like stringing, underextrusion, and elephant's foot (teachingtechyt.github.io). Guides from Simplify3D and Prusa consistently show that small changes in speed, layer height, and first layers have a big impact on adhesion and surface quality (simplify3d.com, Prusa Wissensdatenbank). The "ideal" profile often remains unclear, as results strongly depend on the specific printer, hotend, and filament; therefore, iterative testing is recommended (Printer.tools).
Material, Temperature, and Environment
Materials like ABS or Nylon are more prone to warping and layer separation than PLA because they shrink more and require higher temperatures (Qidi Tech Online Store, All3DP). An enclosed build space, stable room temperature, and adjusted fan curves can significantly mitigate these effects (snapmaker.com). Promises that a single miracle material can rescue all geometries without further measures are exaggerated; reputable sources only mention such solutions as part of the overall package (AzureFilm).
Safety and Emissions
Several studies show that FDM printers release ultrafine particles and VOCs; emission rates vary significantly depending on the material, temperature, and print chamber (American Chemical Society, Nature). Authorities and safety agencies therefore recommend at least well-ventilated rooms or the use of filters (safety.rochester.edu, EPFL). The transferability to typical hobby rooms and long-term concentrations are not yet definitively clarified, which is why pragmatic precautionary measures are advised (Umweltbehörde).
Reactions, Experiences, and Counterarguments
In forums like r/3Dprinting or manufacturer communities, different schools of thought clash: some swear by "profile optimization" in the slicer, while others emphasize mechanics and hardware quality first (Reddit, Ultimaker Community). The discussion as to whether stringing is primarily solved via retraction or more strongly via temperature is typical; experience reports show that both approaches can work but rarely lead to the goal in isolation (Reddit). Similarly controversial are tips for underextrusion: some users report quick success by simply increasing the temperature, while others later discover that a partially clogged nozzle or a dirty extruder was actually the root problem (Reddit). Technical articles and manufacturer-adjacent guides attempt to systematize these experiences by proposing step-by-step diagnostics before blindly changing settings (simplify3d.com, Prusa Wissensdatenbank).
What This Means for You in Everyday Life
When the 10 most common 3D printing errors are understood as diagnostic tools, the workshop becomes more stable and reproducible. The combination of clean first layers, calibrated retraction and temperature values, good mechanics, and a proper environment solves many problems before they arise (simplify3d.com). In our daily work, we see that small, consistent improvements yield significantly more than a single "magic" pro tip.
Open Questions and Data Gaps
Despite many practical reports, there are still gaps: for hobby setups, systematic long-term data on emissions and health effects are lacking (Umweltbehörde). Although studies show that ultrafine particles and VOCs are released and can have potentially harmful effects, their transferability to typical hobby rooms is not yet definitively clarified (American Chemical Society, Frontiers in Public Health). Projects are currently underway involving slicer algorithms and AI-assisted parameterization, the results of which have not yet been widely incorporated into freely accessible practical guides (MDPI). It is important to consider current studies and manufacturer recommendations and to document your own experiences carefully, as many subtleties must be worked out empirically (CDC Stacks).
Conclusion
If you understand the 10 most common 3D printing errors as a toolbox for diagnosis, your workshop will become noticeably more stable and reproducible. A combination of clean first layers, calibrated retraction and temperature values, good mechanics, and a proper environment solves many problems before they even become visible (simplify3d.com). Of course, uncertainties remain – for example, regarding emissions or exotic special materials – but with a critical eye on sources, your own test series, and a small error gallery, you will make significantly more informed decisions. Stringing, warping, layer shifts, and underextrusion will then become old acquaintances rather than specters (Prusa Wissensdatenbank).
- Document your most common error patterns with photos and short notes – this way, you'll recognize patterns much faster.
- For each test print, always change only one parameter block (e.g., retraction, temperature, or speed).
- Create a clean base profile for each material and save it before making adjustments for special cases.
- Ensure a quiet, well-ventilated environment and a mechanically well-maintained printer.
- Use manufacturer guides and community contributions as inspiration, but always validate settings with your own tests.
Also fits well
- Understanding 3D Printing Tolerances
- Storing Filament Correctly
- PLA, PETG, ABS: The Right Plastic for Your Project
- Slicer Basics for Beginners
- Checklist for the First 3D Print Job in an SME