Slicing hangs on large part using thin layers

[zemlin]

I have attached a factory file.
I have to set the layer thickness on this part to 0.3 or more or the slicing will hang. The software does not lock up - it seems to be chewing away, CPU is variable and memory usage climbs. If the layer thickness is at 0.3 it solves in a few seconds. I have let it run for hours without completing. I have to kill the process to get out (the Cancel button doesn't work).

I was going to build this maybe at 0.1 or 0.2, but I can't get it to solve until it's at 0.3. Is there some limitation I should be aware of like a maximum number of lines of G-Code that can fit in one file? Since I'm building this with the open side down, there will be a LOT of support in this model. The bottom half of this housing has the same footprint but is much thinner. I'm seeing the same thing on that part, but the layer thickness limit is much lower. I think I can run that one at 0.15.

[zemlin]

It's not just on big parts. I have a number of washers I was going to print off and I've had the same hang on these parts.
Was going to run 10 each in this file - reduced it down to 4 and 8 and was able to solve at a 0.2 layer, but not 0.15 or 0.1

<update> - I got the washers to print at 0.1 by backing down on the precision settings when exporting the STL file - but that didn't get the housing in the first post going at 0.1 or 0.2 (didn't try others) </update>

<another update> - I was able to get the housing to solve by backing down on the infill percentage and the support percentages - so it seems to be hitting some kind of limit with the number of nodes or some such thing. While it looks like I'll be able to print these parts without issue, any insight into what I'm encountering here would be appreciated. </another update>

[horst.w]

I have attached a factory file.
....

Turn your model upright (Y = 180°) and the slicing will go within 3 sec.

The model ist not verry complicate but the lot of support you need. Print it flat laying on the table without the lip (the lip is than diving in the table and will not be printed); in a second print turn the model in contrary so that only the lip will be seen and be printed. Finally clue the 2 parts together.

To print with only 0.40 mm extrusionwidth but 0.25 mm layer makes no sense for me.

horst.w, GER

[zemlin]

Thank you. I have been breaking some parts into pieces for printing. This one seemed simple enough to do was one part - and yes, I know there's a lot of support.
As far as extrusion width vs. layer depth, I'm new to this 3D printing business (a little over 1 week with the printer) didn't know the width was something I should be messing with. I will look into that.

[horst.w]

washers.factory

you are using "print islands ...", I think that is not needed and makes problems. Also here it is better to turn the big washers laying on their collar
In Additions check the box "Disable Raft Base .." Normally it is not needed also I think the raft is not needed when printing with PLA. I use only Skirt/Brim with 5 - 10 Outlines and only 0.05 mm offset.

H.

[zemlin]

I appreciate your feedback, but the question I am asking is why does the software stop processing? I understand there are many different ways to approach the design and the process. I am new to this process and certainly have a lot to learn. Some of the things I have done on the housing are experiments just so I can see how well things work out - there is some support I'm not sure I will be able to clean up, and other things - but that's for me to learn. I have built this part once - will be changing the design and going at it again.

What I'm really looking to learn here, is why did the slicing process hang?

[horst.w]

Therefore I have no idea, I can only guess the reason.

In the given position your model has a ramp and the ramp has an angle relative to the workplane.
I think that S3D ist not abel to coordinate your given rules with 0.3 mm distance of the support to the object with 0.25 mm layer high.

In upright direction without this ramp the slicer is running normal.

[zemlin]

I'm going to theorize it's related to the density of support and perhaps the number of instructions that result from all of that. I was able to get the part to process with .15mm layers but had to reduce the support infill percentage down to 15% and I think I also had to back down on the Infill density a bit before it would make it all the way through, although the fact that I could also get it to hang on those little washers means there has to be more to it than that.

[zemlin]

I made some progress on this issue tonight. I ran into another model that would not slice. It passed all the tests in the repair menu, but still would cause the slicing to hang. S3d support said the model would slice fine with the default printer profile, so I started looking at settings I had changed.

DENSE SUPPORT LAYERS turned out to be a key on this one. I've been using 5 dense support layers. This model won't slice if I set it to more than 3 layers. Slices in seconds at 3 layers. Hangs at 4.

[1rgteaby]

washers.factory

you are using "print islands ...", I think that is not needed and makes problems. Also here it is better to turn the big washers laying on their collar
In Additions check the box "Disable Raft Base .." Normally it is not needed also I think the raft is not needed when printing with PLA. I use only Skirt/Brim with 5 - 10 Outlines and only 0.05 mm offset.

H.

I have found when using SolidWorks if you get stuck on over hangs. Go into SolidWorks and change to mm and set decimal point at 2 places. When you save your file do a control V the rebuild and save. Then save as your STL file. I design in inches with the decimal point at 8 places. My big files will not print until I make this change. After saving the STL file I set it back to inches