Layer separation (delamination) occurs when printed layers fail to bond properly, causing visible cracks or complete splitting between layers. This severely compromises the structural strength of the part.
Common Causes
- Nozzle temperature too low — Insufficient heat prevents proper fusion between layers
- Cooling fan too aggressive — Excessive airflow cools the current layer before it bonds to the one below
- Drafty print environment — Air currents cause uneven cooling and thermal stress between layers
- Inconsistent extrusion — Partial clogs or filament grinding reduce material flow intermittently
- Layer height too large — Thick layers have less contact pressure and bond weakly
Recommended Fixes
- Increase nozzle temperature by 5-15°C within the filament manufacturer’s range
- Reduce part cooling fan speed (especially for ABS, ASA, and PETG)
- Use an enclosure to maintain stable ambient temperature around the print
- Check for consistent extrusion — perform a cold pull to clear any partial clogs
- Reduce layer height to improve inter-layer adhesion (0.2mm or less)
- Slow down print speed to give layers more time to bond
- Ensure filament is dry — moisture causes steam that weakens layer bonds