Mastering the Art: How to Perfect Your PLA 3D Printing

Introduction

In the realm of creation and innovation, a master craftsman is someone who has honed their skills to the point of artistry. They understand their tools, materials, and techniques deeply, allowing them to produce works of exceptional quality and precision. Becoming a master in any craft requires dedication, knowledge, and a willingness to continually learn and improve. In this series of articles, we aim to guide you on your journey to becoming a master craftsman in the world of 3D printing, starting with an essential foundation: understanding your materials, beginning with PLA.

What is PLA?

Polylactic Acid (PLA) is a biodegradable plastic derived from renewable resources such as cornstarch. Unlike traditional plastics, which are derived from petroleum, PLA is produced through a fermentation process involving natural plant sugars. This makes PLA not only a sustainable option but also one that significantly reduces the environmental impact associated with plastic production and disposal.

Imagine printing your designs using a material that helps reduce our reliance on fossil fuels and supports a more sustainable future. By choosing PLA, you contribute to decreasing plastic waste while creating works of art and parts to your heart's desire in the comfort of your own home .

A Brief History of PLA

The development of PLA dates back to the early 20th century, but it wasn't until the late 1980s and early 1990s that significant advancements were made. Here’s a brief timeline:

- 1932: Wallace Carothers, working at DuPont, first synthesized polylactic acid in the laboratory. However, it wasn’t pursued commercially due to the cost and limited applications at the time.

- 1980s: Interest in biodegradable plastics resurged, driven by environmental concerns. Cargill, an agricultural company, began exploring the potential of PLA.

- 1990s: Cargill Dow LLC (later becoming NatureWorks LLC) developed a cost-effective process to produce PLA from renewable resources. This breakthrough made PLA commercially viable.

- 2000s: PLA started being used in various industries, from packaging to disposable items. Its application in 3D printing emerged as the technology became more accessible to consumers and hobbyists.

PLA's rise in popularity was fueled by its environmental friendliness and ease of use, making it a preferred material in the 3D printing community.

What Properties make PLA unique?

- Biodegradability: PLA is biodegradable under industrial composting conditions, breaking down into water, carbon dioxide, and organic materials within a few months. This eco-friendly trait is a significant advantage in a world increasingly focused on green manufacturing and safety

- Melting Point and Thermal Properties: PLA has a melting point between 180°C and 220°C. This lower melting point compared to other filaments like ABS means less energy consumption and easier printing. However, this also means PLA isn’t suited for high-temperature applications—don’t leave your PLA prints in a hot car!

- Odor and Safety: Printing with PLA emits a sweet, slightly pleasant odor, unlike the harsh fumes from materials like ABS. This makes it safer and more comfortable to use, especially in enclosed or poorly ventilated spaces. Think of it as the pleasant aroma of baking bread compared to burning rubber.

- Mechanical Properties: PLA is known for its good tensile strength and rigidity, which makes it great for creating detailed and aesthetically pleasing prints. However, it’s also more brittle compared to filaments like PETG or ABS. While it might not be the best for parts that need to withstand significant stress, it’s perfect for prototypes, models, and decorative items.

- Optical Properties: PLA is available in a wide variety of colors and finishes, including opaque, translucent, and specialty blends like glow-in-the-dark or wood-filled. This diversity allows for creative and visually appealing prints. Want to print a neon-green dragon or a wood-textured vase? PLA’s got you covered.

- Chemical Resistance: PLA has moderate chemical resistance. It is resistant to many common chemicals, such as acetone and oils, and it is not significantly affected by alcohol. However, PLA is not resistant to strong solvents, such as chlorinated solvents and aromatic hydrocarbons, which can cause it to degrade or dissolve. This makes it less suitable for applications where exposure to harsh chemicals is expected. Additionally, prolonged exposure to water can cause PLA to absorb moisture and degrade over time, although this is typically a slow process.

What are the Advantages of Using PLA?

- Ease of Use: PLA is incredibly user-friendly, especially for beginners. Its lower printing temperature, excellent bed adhesion, and minimal warping issues make it a go-to filament for those new to 3D printing. You don’t need to be a seasoned pro to get great results with PLA.

- Environmental Benefits: As a biodegradable material derived from renewable resources, PLA is a more environmentally friendly option than traditional plastics. This makes it a favorite among eco-conscious makers and industries. Printing with PLA can give you a little extra peace of mind knowing you're not contributing to the growing plastic waste problem.

- Surface Finish and Detail: PLA produces parts with excellent surface finish and detail, thanks to its low shrinkage rate. This makes it ideal for creating intricate and detailed models, prototypes, and decorative items. If you’re looking to impress with sharp, clean prints, PLA won’t disappoint.

- Variety and Availability: PLA is widely available and comes in an extensive range of colors and specialty formulations. This versatility allows users to choose the perfect filament for their specific project needs, whether for artistic endeavors, functional prototypes, or educational tools.

New and Exciting PLA Formulations

While traditional PLA is already a fantastic filament, manufacturers have been developing new and exciting formulations to meet various conditions and requirements. Some examples include:

- High-Speed PLA: With the advent of newer generation high-speed 3D printers, filament manufacturers are developing PLA formulations that can handle higher printing speeds without compromising quality. These high-speed PLA filaments maintain their structural integrity and finish even at increased printing velocities, making them ideal for rapid prototyping and production. Examples include [eSun's PLA+](https://www.esun3d.net/products/pla_plus.html) and [Polymaker's PolyTerra PLA](https://www.polymaker.com/product/polyterra-pla/).

- High-Temperature PLA: Designed to withstand higher temperatures than standard PLA, high-temperature PLA formulations are suitable for applications where increased heat resistance is necessary, such as automotive parts or functional prototypes for hot environments. Examples include [Polymaker's PolyLite™ PLA HT](https://www.polymaker.com/product/polylite-pla/) and [ColorFabb's HTPLA](https://colorfabb.com/htpla/).

- Flexible PLA: Flex PLA combines the ease of printing with PLA with the flexibility of materials like TPU (thermoplastic polyurethane). It's ideal for printing objects that need to bend or flex without breaking, such as phone cases, shoe insoles, or hinges. [Taulman3D's Taulman T-Glase Flexible](https://taulman3d.com/t-glase.html) and [NinjaTek's NinjaFlex](https://ninjatek.com/products/3d-filaments/ninjaflex/) are popular choices for flexible PLA.

- Engineering-Grade PLA: Engineered PLA formulations are reinforced with additives to enhance mechanical properties such as strength, impact resistance, and heat deflection. These filaments are suitable for functional parts that require durability and reliability, such as gears, brackets, and tooling components. Examples include [Proto-pasta's HTPLA](https://www.proto-pasta.com/products/high-temperature-pla) and [Formfutura's EasyFil™ Engineering PLA](https://formfutura.com/shop/product/easyfil-pla/).

What are the best Applications of PLA?

PLA's versatility and user-friendly characteristics make it suitable for a wide range of applications. Here are some common uses of PLA filament in various fields:

- Prototyping and Concept Models: PLA is ideal for creating prototypes and concept models due to its ease of use and excellent surface finish. Designers and engineers can quickly iterate on designs and produce visually appealing models for presentation and testing.

- Educational Projects: PLA's safety and ease of use make it a popular choice in educational settings. Students can learn about 3D printing technology and create models for science, technology, engineering, and mathematics (STEM) projects without concerns about toxic fumes or complex printing requirements.

- Decorative Items and Art: The wide variety of colors and finishes available for PLA makes it perfect for creating decorative items, art pieces, and toys. Artists and hobbyists can experiment with different formulations to achieve unique visual effects.

- Functional Parts: While PLA is not as durable as other filaments like PETG or ABS, it can still be used for functional parts that do not require high impact resistance or heat tolerance. This includes items like custom enclosures, fixtures, and tools for light-duty applications.

- Packaging and Disposable Items: PLA's biodegradability makes it a suitable material for creating eco-friendly packaging and disposable items. Companies are increasingly exploring PLA as an alternative to traditional plastics for products like food containers, cutlery, and other single-use items.

Best Practices for Printing with PLA

To achieve optimal results when printing with PLA, it's essential to follow certain guidelines and best practices. Here are some key considerations:

- Print Temperature: Start with a nozzle temperature around 200°C. Depending on the specific brand and formulation of PLA, you might need to adjust this temperature slightly.

- Bed Temperature: While PLA can print without a heated bed when needed, using one is highly recommended to improve bed adhesion and reduce the risk of warping. Set the bed temperature to around 60°C for your textured plates. (more on these in later articles)

Ambient temp for cool plates.

-Print Speed: PLA prints well at speeds between 60-100 mm/s. For high-detail prints, slower speeds around 30-50 mm/s can enhance the quality and precision of the final product.

- Cooling: PLA benefits significantly from active cooling. Use a part cooling fan to solidify the filament quickly after extrusion.

- Storage: PLA is hygroscopic, meaning it absorbs moisture from the air, which can negatively impact print quality. Store PLA in a cool, dry place, ideally in a sealed bag with desiccant packs to keep it dry.

Modern PEI Textured Build Surfaces

Ensuring good bed adhesion is critical to achieving successful 3D prints, especially with PLA. Modern PEI (Polyetherimide) textured build surfaces have revolutionized the way we approach bed adhesion. Here’s why they are so effective:

- Surface Texture: The textured surface of PEI sheets provides excellent grip for the first layer of the print, ensuring it sticks well and reduces the likelihood of warping or lifting during the printing process. This texture creates a slight mechanical bond between the print and the bed.

- Increased Surface Area: The textured finish of PEI build surfaces increases the surface area contact between the print and the bed. This larger contact area enhances the adhesion, helping the print to stay firmly in place even during long or complex prints.

- Ease of Use: PEI sheets are easy to use and maintain. They do not require additional adhesives like glue sticks or hairspray to achieve good adhesion. Simply clean the PEI surface with isopropyl alcohol to remove any residue and ensure optimal adhesion for subsequent prints.

- Durability: PEI sheets are durable and can withstand numerous print cycles without degrading. They maintain their adhesive properties over time, providing consistent and reliable performance for countless prints. This durability makes them a cost-effective solution for 3D printing enthusiasts and professionals alike.

In future articles, we will be exploring a variety of different textured build surfaces to help you achieve the best possible adhesion and print quality as well as some really neat optical effects.

Troubleshooting Common PLA Printing Issues

Even with the best practices in place, you might encounter some common issues when printing with PLA. Here are a few tips to troubleshoot these problems:

- Stringing: If your prints have thin strands of filament between parts, try lowering the printing temperature slightly or adjusting the retraction settings in your slicer software.

- Warping: To prevent the corners of your print from lifting off the build plate, ensure the bed is level, use a heated bed, and consider using a brim or raft to increase adhesion.

- Under-Extrusion: If your prints have gaps or weak spots, check for clogs in the nozzle, ensure the filament is feeding smoothly, and verify that the extrusion multiplier or flow rate is correctly set in your slicer.

- Layer Shifts: If your print layers are misaligned, make sure the belts on your printer are tight, the print bed is stable, and the printer is clear of debris. Layer shifts are usually a mechanical issue, especially if not caused by a bed adhesion problem.

- Brittle Prints: PLA prints can be brittle, especially if the filament has absorbed moisture. Ensure proper storage to keep the filament dry, and consider annealing your prints (baking them at a low temperature) to improve their mechanical properties and reduce brittleness.

Conclusion: Mastering the art with PLA Knowledge

Understanding PLA filament is a crucial step on the path to becoming a master craftsman in 3D printing. Mastery in any field comes from a deep understanding of the materials and tools at your disposal. By comprehending the properties, advantages, and best practices for PLA, as well as staying informed about new formulations, you can enhance your printing skills and produce high-quality, precise, and innovative prints.

This knowledge not only allows you to troubleshoot common issues effectively but also empowers you to choose the right PLA formulation for each specific project, optimizing both performance and aesthetics. A master craftsman uses this information to make the perfect choice for the application, whether you’re creating detailed prototypes, educational models, or artistic pieces. The insights gained from understanding PLA will elevate your craftsmanship and set you on the path to 3D printing mastery. Knowing more about your materials can give you an advantage over most, enabling you to make informed decisions that improve your printing results and efficiency.

As we move forward in this series of articles, I will be exploring new materials, machines, and "how to's," sharing my findings and failures along the way to help cultivate your curiosity and encourage your creativity. Stay tuned for more insights and updates in the ever-evolving world of 3D printing.

Recommended YouTube Channels for 3D Printing

To further enhance your skills and knowledge in 3D printing, here are five YouTube channels that offer valuable resources, tutorials, and tips:

- Teaching Tech: A comprehensive channel offering in-depth tutorials, reviews, and guides on various 3D printing topics. The host, Michael, covers everything from beginner basics to advanced techniques, making it a great resource for all skill levels. [Link](https://www.youtube.com/channel/UCbgBDBrwsikmtoLqtpc59Bw)

- The Feral Engineer: This channel provides a mix of practical projects, reviews, and tutorials focused on 3D printing and engineering. The host’s hands-on approach and detailed explanations make complex topics accessible and engaging. [Link](https://www.youtube.com/channel/UClUfdWZaXRq_FakxSnMyj5A)

- Maker's Muse: Angus Deveson runs this channel, which is known for its creative projects, product reviews, and in-depth tutorials. Maker's Muse is perfect for those looking to explore the artistic and innovative side of 3D printing. [Link](https://www.youtube.com/user/TheMakersMuse)

- 3D Printing Nerd: Joel Telling, the 3D Printing Nerd, shares his passion for 3D printing through reviews, tutorials, and community projects. His enthusiastic and entertaining style makes learning about 3D printing enjoyable and informative. [Link](https://www.youtube.com/user/3DPrintingNerd)

- 3D Maker Noob: With a focus on product reviews, build guides, and practical printing tips, 3D Maker Noob provides valuable insights for both beginners and experienced 3D printing enthusiasts. The channel is known for its detailed and honest content. [Link](https://www.youtube.com/user/3DMakerNoob)

By following these channels, you’ll gain access to a wealth of information and inspiration to help you master the craft of 3D printing.

Still curious?: Get Involved

I encourage you to get involved and become a part of this learning journey. If you have any questions about PLA or other 3D printing topics, feel free to ask. Your inquiries can help shape future articles and ensure that we cover the topics that matter most to you. Together, we can cultivate curiosity, encourage creativity, and advance our skills in the ever-evolving world of 3D printing. Stay curious, stay creative, and keep printing!