Optimizing support removal with 3DXTech HTS material, Z-offset calibration, and nanopolymer adhesives for industrial-grade performance.
Why This PEKK Print Needed More Than Standard Support
When a customer requested a functional part for use inside an engine bay, it introduced tough challenges: exposure to oil, heat, and dripping fluids. The print demanded high mechanical strength and resistance to extreme conditions. Standard supports weren’t cutting it—the angled holes and deep cavities required a dedicated support strategy to avoid impossible post-processing.
Switching to Dual Nozzles with 3DXTech HTS Support
The breakthrough came from leveraging the 22 IDEX dual independent extruder system. By dedicating one nozzle to 3DXTech HTS high-temp breakaway support, the team achieved smoother bottom layers, improved overhang support, and a far easier removal process. HTS, when properly tuned, allowed clean separation without damaging the functional part surfaces.
Z-Offset Calibration: The Game-Changer
Dialing in the Z-offset between the part and support proved critical. Initial attempts at 0.0 mm were too difficult to remove, while excessive gaps caused poor adhesion. Through iterative tuning, the sweet spot was found at 0.14 mm, delivering consistent, reliable separation without sacrificing part quality.
Advanced Support Tuning Tricks
- Breaking Lines: Strategic gaps in the support let large pieces snap apart like a cracker, simplifying removal.
- Interface Layers: Using at least 10 dense interface layers provided strong grip for peeling supports off cleanly in one piece.
- Tree Support Density: Higher density organic tree supports ensured stability for angled holes and reduced risk of partial tearing.
The Importance of PEKK First Layer Adhesion
No print succeeds without a reliable first layer. Using nanopolymer adhesive ensured consistent adhesion across the build plate, eliminated the need for brims, and allowed parts to release naturally as the plate cooled. This adhesive played a key role in preventing warping with high-temp nylon and composite filaments.
Results: A Production-Ready Engine Bay Part
The final part emerged with clean cavities, strong structural integrity, and easy-to-remove supports. What started as an impossible single-nozzle challenge was solved with dual extrusion, HTS breakaway material, Z-offset fine-tuning, and smart support strategies. The 22 IDEX proved its worth not just in speed (mirror and duplicate mode) but in printing geometries that single-nozzle systems struggle with.
Takeaways for Industrial 3D Printing
This project highlighted the importance of:
- Leveraging dual-nozzle systems for complex, high-performance applications.
- Tuning Z-offsets carefully for breakaway materials.
- Strengthening supports with higher density and multiple interface layers.
- Using adhesives like nanopolymer to ensure reliable first-layer bonding.
For those running industrial-grade jobs, these techniques can make the difference between a failed print and a production-ready component.