3D Printing Failures We See Every Week

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Common 3D Printing Mistakes and How to Avoid Them

These problems are not signs of inexperience—they are normal.

In a makerspace, we see the same 3D printing failures week after week. Understanding these basics improves outcomes for everyone and reduces wear, downtime, and frustration.

1. Treating the Printer Like an Appliance

The most persistent mistake is assuming the printer will compensate for poor setup or design decisions.

Beginners often expect:

  • automatic leveling to fix everything
  • slicer defaults to be "good enough"
  • the printer to adapt to bad geometry

In reality, 3D printers are unforgiving. Small deviations in leveling, temperature, or material quality produce visible failures. The machine will not warn you before wasting six hours of print time.

Correction: Understand that printing is a process, not a button. Setup and verification are part of the job.

2. Ignoring First-Layer Quality

If the first layer is wrong, the print is already failed.

Common symptoms:

  • corners lifting
  • lines not sticking
  • nozzle dragging through plastic

Beginners often respond by increasing print speed or restarting repeatedly, instead of diagnosing adhesion.

What's usually wrong:

  • bed not level relative to the nozzle
  • incorrect Z-offset
  • dirty or inappropriate build surface
  • wrong bed temperature for the material
Correction: Slow the first layer down. Verify squish visually. If the first layer isn't clean, stop the print.

3. Using the Wrong Material for the Job

PLA is not a universal solution, but beginners treat it as one.

We regularly see:

  • PLA parts used near heat sources
  • structural parts printed in brittle materials
  • outdoor parts printed without UV resistance

This leads to warped parts, cracks, and rapid failure.

Correction: Choose materials based on environment and load, not convenience. Ask before printing if the part matters.

4. Overtrusting Slicer Defaults

Slicers are optimized for speed of onboarding, not correctness.

Defaults often assume:

  • simple geometry
  • cosmetic parts
  • ideal cooling
  • no tolerance requirements

Beginners rely on these defaults even when printing mechanical components.

Common results:

  • weak layer bonding
  • unnecessary supports
  • poor surface finish on functional faces
Correction: Learn what infill, wall count, orientation, and layer height actually do. Defaults are a starting point, not a solution.

5. Designing Parts That Shouldn't Be 3D Printed

Not every object belongs on a printer.

We frequently see:

  • flat panels better suited to laser cutting
  • load-bearing parts that should be machined
  • assemblies printed as one piece for convenience

3D printing excels at complex geometry, not strength, speed, or surface finish.

Correction: Start by asking whether 3D printing is the right tool. In a makerspace, it often isn't the only option.

6. Ignoring Orientation and Load Direction

Print orientation determines strength. Beginners rarely account for this.

Layer lines are failure planes. Printing a bracket vertically when it will be loaded horizontally is a predictable mistake.

Correction: Orient parts so forces act across layers, not between them. Strength is directional in printed parts.

7. Printing Without Tolerances

Beginners expect parts to fit together exactly as modeled.

They do not.

Shrinkage, extrusion width, and layer height all affect final dimensions. Press-fit parts designed at nominal dimensions usually fail.

Correction: Design with clearance. Test small sections before committing to full prints.

8. Walking Away From Long Prints Unchecked

Starting a long print and leaving immediately is common—and risky.

Failures often occur in the first 10–20 minutes:

  • bed adhesion issues
  • under-extrusion
  • cooling problems

By the time someone returns, filament and time are already wasted.

Correction: Stay for the first layers. Confirm stability before leaving.

Why We Emphasize These Mistakes

These problems are not signs of inexperience. They are normal. The issue is that most online content minimizes them or frames failure as user error rather than a learning signal.

In a makerspace, shared equipment means mistakes affect more than one person. Understanding these basics improves outcomes for everyone and reduces wear, downtime, and frustration.

3D printing rewards patience, observation, and iteration. Treat it accordingly.

Ready to Learn 3D Printing the Right Way?

Visit Our 3D Printing Lab

Kalamazoo Makerspace offers hands-on training, multiple FDM printers, and a community of experienced makers who can help you avoid these common mistakes.

  • Learn proper bed leveling and first-layer techniques
  • Get guidance on material selection for your project
  • Understand slicer settings beyond the defaults
  • Design parts that work with 3D printing's strengths
Explore Our 3D Printing Lab

Combine with Other Tools

Many of these failures can be avoided by choosing the right fabrication method. Our makerspace offers:

  • Laser cutting for flat panels and precise 2D parts
  • CNC routing for stronger wooden components
  • Metal shop for load-bearing brackets and fixtures
  • Electronics lab for integrating your printed parts
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Want to see the space in person? Schedule a tour and talk to members who print regularly.

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