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lw-pla-print-settings.md

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Types of LW-PLA

On the market, there are many types of LW-PLA available. The key difference among them is whether they are in the prefoamed or active foaming technology. Both types of filaments are well-suited for printing airplanes; however, recommended print settings will differ between them. Prefoamed filaments are typically more expensive, but they offer the potential for higher print quality and a lower risk of artifacts that may occasionally occur during active foaming printing.

How are Flightory aircraft designed?

Flightory airplanes are designed primarily for printing with LW-PLA, with additional components printed from rigid materials such as PET-G, PLA, or ABS. Each airplane has its own instructions, specifying settings for infill and wall line count for each individual part. The general rule is to print fuselages with a gyroid infill of 3%, while wings should be printed with a cubic subdivision infill of 3%. If there are any exceptions, they are noted in the instructions for a specific aircraft. Infill settings and wall thickness can be configured and changed; however, the selected settings represent an optimal compromise between the durability and strength of the airframe and its weight. The airplanes are designed to be printable on standard, inexpensive printers with a small working area. Most elements fit within a 220x220x250mm working area. Prototypes are tested on Tarantula Pro printers with a standard 0.4mm nozzle. Many users, however, choose to make modifications and experiment with other materials, such as printing whole airframes with ABS, PLA, or other harder materials. While this is possible, it should be noted that it may result in increased weight and require different settings optimized for the specific material being used.

Optimal print settings

The recommended slicer for Flightory models is Ultimaker Cura, as it offers extensive configuration possibilities and produces great printing results. Below are detailed settings for Active Foaming and Prefoamed LW-PLA. Many settings overlap, but there are specific differences in temperature, retract, and flow. If you want to use other slicers, you can experiment based on these settings. Below are the detailed print settings for Cura Slicer.

Filament used for printing Flightory prototypes

Below are the detailed print settings in the Cura slicer for active foaming and prefoamed LW-PLA. It’s important to note that the filaments used for these settings are eSUN ePLA-LW (active foaming) and Polymaker Polylite LW-PLA (prefoamed). Other manufacturers’ filaments can also be used successfully, but there may be some differences between them that might require tuning the settings, such as slight adjustments in temperature, flow, retraction, etc. Feel free to experiment and share your experiences with the community.

Active Foaming LW-PLA Settings

Quality
Layer Height 0.25 mm
Initial Layer Height 0.25 mm
Line Width 0.4 mm
Wall Line Width 0.4 mm
Outer Wall Line Width 0.4 mm
Inner Wall(s) Line Width 0.4 mm
Top/Bottom Line Width 0.4 mm
Infill Line Width 0.4 mm
Skirt/Brim Line Width 0.4 mm
Initial Layer Line Width 100%

Walls

Walls
Wall Thickness 0.4 mm
Wall Line Count 1
Outer Wall Wipe Distance 0.0 mm
Outer Wall Inset 0.0 mm
Optimize Wall Printing Order
Wall Ordering Inside to Outside
Alternate Extra Wall
Print Thin Walls
Horizontal Expansion 0.0 mm
Initial Layer Horizontal Expansion 0.0 mm
Hole Horizontal Expansion 0.0 mm
Z Seam Alignment Sharpest Corner
Seam Corner Preference Smart Hiding

Top/Bottom

Top/Bottom
Top Surface Skin Layers 0
Top/Bottom Thickness 0.75 mm
Top Thickness 0.75 mm
Top Layers 3
Bottom Thickness 0.75 mm
Bottom Layers 3
Top/Bottom Pattern Lines
Bottom Pattern Initial Layer Lines
Monotonic Top/Bottom Order
Top/Bottom Line Directions
No Skin in Z Gaps
Extra Skin Wall Count 1
Enable Ironing
Skin Overlap Percentage 10%
Skin Overlap 0.04 mm
Skin Removal Width 0.4 mm
Top Skin Removal Width 0.4 mm
Bottom Skin Removal Width 0.4 mm
Skin Expand Distance 0.4 mm
Top Skin Expand Distance 0.4 mm
Bottom Skin Expand Distance 0.4 mm
Maximum Skin Angle for Expansion 90°
Minimum Skin Width for Expansion 0.0 mm

Infill (Gyroid)

Infill (Gyroid)
Infill Density 3%
Infill Line Distance 13.333 mm
Infill Pattern Gyroid
Connect Infill Lines
Randomize Infill Start
Infill Line Multiplier 1
Extra Infill Wall Count 0
Infill Overlap Percentage 10%
Infill Overlap 0.04 mm
Infill Wipe Distance 0.1 mm
Infill Layer Thickness 0.25 mm
Gradual Infill Steps 0
Infill Before Walls
Infill Minimum Area 0.0 mm
Infill Support
Skin Edge Support Thickness 0.0 mm
Skin Edge Support Layers 0

Infill (Cubic Subdivision)

Infill (Cubic Subdivision)
Infill Density 3%
Infill Line Distance 40.0 mm
Infill Pattern Cubic Subdivision
Infill Line Directions
Randomize Infill Start
Infill Line Multiplier 1
Cubic Subdivision Shell 0.4 mm
Infill Overlap Percentage 10%
Infill Overlap 0.04 mm
Infill Wipe Distance 0.1 mm
Infill Layer Thickness 0.25 mm
Gradual Infill Steps 0
Infill Before Walls
Infill Minimum Area 0.0 mm
Infill Support
Skin Edge Support Thickness 0.0 mm
Skin Edge Support Layers 0

Material

Material
Printing Temperature 235 °C
Printing Temperature Initial Layer 235 °C
Initial Printing Temperature 235 °C
Final Printing Temperature 235 °C
Build Plate Temperature 60 °C
Build Plate Temperature Initial Layer 60 °C
Scaling Factor Shrinkage Compensation 100%
Horizontal Scaling Factor Shrinkage Compensation 100%
Vertical Scaling Factor Shrinkage Compensation 100%
Flow 60%
Wall Flow 60%
Outer Wall Flow 60%
Inner Wall(s) Flow 60%
Top/Bottom Flow 60%
Infill Flow 60%
Skirt/Brim Flow 60%
Prime Tower Flow 60%
Initial Layer Flow 80%

Speed

Speed
Print Speed 60 mm/s
Infill Speed 60 mm/s
Wall Speed 30 mm/s
Outer Wall Speed 30 mm/s
Inner Wall Speed 30 mm/s
Top/Bottom Speed 30 mm/s
Travel Speed 120 mm/s
Initial Layer Speed 30 mm/s
Initial Layer Print Speed 30 mm/s
Initial Layer Travel Speed 120 mm/s
Skirt/Brim Speed 30 mm/s
Number of Slower Layers 2
Flow Equalization Ratio 100%
Enable Acceleration Control
Enable Jerk Control

Travel

Travel
Enable Retraction
Retract at Layer Change
Retraction Distance 0.0 mm
Retraction Speed 35 mm/s
Retraction Retract Speed 35 mm/s
Retraction Prime Speed 35 mm/s
Retraction Extra Prime Amount 0.3 mm
Retraction Minimum Travel 1.5 mm
Maximum Retraction Count 90
Minimum Extrusion Distance Window 6.5 mm
Combing Mode All
Avoid Supports When Traveling
Travel Avoid Distance 0.625 mm
Layer Start X 0.0 mm
Layer Start Y 0.0 mm
Z Hop When Retracted

Cooling

Cooling
Enable Print Cooling
Regular/Maximum Fan Speed Threshold 10 s
Regular Fan Speed at Height 0.27 mm
Regular Fan Speed at Layer 2
Minimum Layer Time 2.0 s
Maximum Speed 10 mm/s
Lift Head

Support

Support
Generate Support

Build Plate Adhesion

Build Plate Adhesion
Build Plate Adhesion Type Brim
Skirt/Brim Minimum Length 250 mm
Brim Width 8.0 mm
Brim Line Count 20
Brim Distance 0.0 mm
Brim Only on Outside

Prefoamed LW-PLA Settings

Quality
Layer Height 0.25 mm
Initial Layer Height 0.25 mm
Line Width 0.4 mm
Wall Line Width 0.4 mm
Outer Wall Line Width 0.4 mm
Inner Wall(s) Line Width 0.4 mm
Top/Bottom Line Width 0.4 mm
Infill Line Width 0.4 mm
Skirt/Brim Line Width 0.4 mm
Initial Layer Line Width 100%

Walls

Walls
Wall Thickness 0.4 mm
Wall Line Count 1
Outer Wall Wipe Distance 0.0 mm
Outer Wall Inset 0.0 mm
Optimize Wall Printing Order
Wall Ordering Inside to Outside
Alternate Extra Wall
Print Thin Walls
Horizontal Expansion 0.0 mm
Initial Layer Horizontal Expansion 0.0 mm
Hole Horizontal Expansion 0.0 mm
Z Seam Alignment Sharpest Corner
Seam Corner Preference Smart Hiding

Top/Bottom

Top/Bottom
Top Surface Skin Layers 0
Top/Bottom Thickness 0.75 mm
Top Thickness 0.75 mm
Top Layers 3
Bottom Thickness 0.75 mm
Bottom Layers 3
Top/Bottom Pattern Lines
Bottom Pattern Initial Layer Lines
Monotonic Top/Bottom Order
Top/Bottom Line Directions
No Skin in Z Gaps
Extra Skin Wall Count 1
Enable Ironing
Skin Overlap Percentage 10%
Skin Overlap 0.04 mm
Skin Removal Width 0.4 mm
Top Skin Removal Width 0.4 mm
Bottom Skin Removal Width 0.4 mm
Skin Expand Distance 0.4 mm
Top Skin Expand Distance 0.4 mm
Bottom Skin Expand Distance 0.4 mm
Maximum Skin Angle for Expansion 90°
Minimum Skin Width for Expansion 0.0 mm

Infill (Gyroid)

Infill (Gyroid)
Infill Density 3%
Infill Line Distance 13.333 mm
Infill Pattern Gyroid
Connect Infill Lines
Randomize Infill Start
Infill Line Multiplier 1
Extra Infill Wall Count 0
Infill Overlap Percentage 10%
Infill Overlap 0.04 mm
Infill Wipe Distance 0.1 mm
Infill Layer Thickness 0.25 mm
Gradual Infill Steps 0
Infill Before Walls
Infill Minimum Area 0.0 mm
Infill Support
Skin Edge Support Thickness 0.0 mm
Skin Edge Support Layers 0

Infill (Cubic Subdivision)

Infill (Cubic Subdivision)
Infill Density 3%
Infill Line Distance 40.0 mm
Infill Pattern Cubic Subdivision
Infill Line Directions
Randomize Infill Start
Infill Line Multiplier 1
Cubic Subdivision Shell 0.4 mm
Infill Overlap Percentage 10%
Infill Overlap 0.04 mm
Infill Wipe Distance 0.1 mm
Infill Layer Thickness 0.25 mm
Gradual Infill Steps 0
Infill Before Walls
Infill Minimum Area 0.0 mm
Infill Support
Skin Edge Support Thickness 0.0 mm
Skin Edge Support Layers 0

Material

Material
Printing Temperature 210 °C
Printing Temperature Initial Layer 210 °C
Initial Printing Temperature 210 °C
Final Printing Temperature 210 °C
Build Plate Temperature 60 °C
Build Plate Temperature Initial Layer 60 °C
Scaling Factor Shrinkage Compensation 100%
Horizontal Scaling Factor Shrinkage Compensation 100%
Vertical Scaling Factor Shrinkage Compensation 100%
Flow 100%
Wall Flow 100%
Outer Wall Flow 100%
Inner Wall(s) Flow 100%
Top/Bottom Flow 100%
Infill Flow 100%
Skirt/Brim Flow 100%
Prime Tower Flow 100%
Initial Layer Flow 100%

Speed

Speed
Print Speed 60 mm/s
Infill Speed 60 mm/s
Wall Speed 30 mm/s
Outer Wall Speed 30 mm/s
Inner Wall Speed 30 mm/s
Top/Bottom Speed 30 mm/s
Travel Speed 120 mm/s
Initial Layer Speed 30 mm/s
Initial Layer Print Speed 30 mm/s
Initial Layer Travel Speed 120 mm/s
Skirt/Brim Speed 30 mm/s
Number of Slower Layers 2
Flow Equalization Ratio 100%
Enable Acceleration Control
Enable Jerk Control

Travel

Travel
Enable Retraction
Retract at Layer Change
Retraction Distance 6.0 mm
Retraction Speed 50 mm/s
Retraction Retract Speed 50 mm/s
Retraction Prime Speed 50 mm/s
Retraction Extra Prime Amount 0.0 mm
Retraction Minimum Travel 1.5 mm
Maximum Retraction Count 90
Minimum Extrusion Distance Window 6.5 mm
Combing Mode All
Avoid Supports When Traveling
Travel Avoid Distance 0.625 mm
Layer Start X 0.0 mm
Layer Start Y 0.0 mm
Z Hop When Retracted

Cooling

Cooling
Enable Print Cooling
Regular/Maximum Fan Speed Threshold 10 s
Regular Fan Speed at Height 0.27 mm
Regular Fan Speed at Layer 2
Minimum Layer Time 2.0 s
Maximum Speed 10 mm/s
Lift Head

Support

Support
Generate Support

Build Plate Adhesion

Build Plate Adhesion
Build Plate Adhesion Type Brim
Skirt/Brim Minimum Length 250 mm
Brim Width 8.0 mm
Brim Line Count 20
Brim Distance 0.0 mm
Brim Only on Outside

These settings are intended to optimize the printing process for Prefoamed LW-PLA, ensuring a balance between print quality and material efficiency. Adjustments may be necessary based on specific printer models and environmental conditions.