Pinholes and voids come from moisture, under-extrusion, trapped air, poor layer bonding or contaminated material. Correct the extrusion chain before changing unrelated settings.
Check material
- Dry the spool.
- Measure diameter.
- Inspect contamination.
Check process
Calibrate flow, check nozzle condition and stabilise temperature. Reduce speed if pressure cannot keep up.
Validate
- Surface.
- Cross-section.
- Strength.
- Dimensions.
| Symptom | Cause | Action |
|---|---|---|
| Random holes | Moisture | Dry |
| Regular voids | Under-extrusion | Calibrate |
| Dark specks | Contamination | Clean |
| Weak layers | Temperature | Stabilise |
Common engineering mistakes
- Only increasing flow.
- Ignoring moisture.
- Changing everything.
- Not inspecting the part.
- Using one sample.
Buyer checklist
- Is the filament dry?
- Is flow calibrated?
- Is nozzle clean?
- Is temperature stable?
- Are voids repeatable?
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