Reducing Printing Noise Levels

It’s a well-known fact that 3D printers, including my Prusa Mini, are far from being quiet machines. Although my printer isn’t excessively loud, it can still be quite annoying when it starts running. To make matters worse, it’s located in the same room where I work during the day, so I’m constantly subjected to its noise. The problem is exacerbated by the room’s layout and the position of the printer. My workspace is a brick cube where noise can reverberate freely, and the table that the printer sits on is made of MDF with an open frame, amplifying and spreading the noise throughout the room.

Stock Printer Benchmark

To evaluate the default noise levels of the printer, I must first obtain relevant data. Regrettably, the location of the printer cannot be altered as the room has been designed to accommodate it. However, the printer will remain in the room to ensure ease of access and monitoring. The calibration cube, with a standard size of 20mm, will be printed during each of the modifications. Throughout the printing process, a mobile application will record the minimum, average, and maximum noise levels.

Results

Based on my observations, the noise levels I measured during the printing process were not surprising. The minimum noise level was 39 decibels, the average was 58 decibels, and the maximum noise level was 68 decibels. The majority of the noise was concentrated at the beginning of the printing process when the printer was homing and checking the bed level. During this stage, the printer was making frequent movements to ensure that the bed was level. The only other instances of loud noises were when a layer change occurred. During this time, the printer had to make a quick acceleration from the end of the infill to the perimeter of the cube on the next layer, which resulted in a loud noise.

Printed Shock Feet

The first modification I am planning to do is to create shock-absorbing feet that can be attached to the base of my Prusa Mini 3D printer. These feet will help to absorb some of the vibrations produced by the printer during operation, thus preventing them from being transferred to the tabletop.

Although the feet can be printed using any material, PETG is the preferred choice because it is more flexible than PLA, which tends to deform and crack over time.

Shock Feet Results

After fitting the feet and stabilizing the printer to prevent excessive vibration and bouncing, the print results were impressive. It is crucial to check for any issues introduced, as adding feet can change the printer. The noise level readings revealed interesting results, as there was no similar change across the minimum, average, and maximum. This variation is likely due to the different frequencies that the feet can handle. The minimum noise level was at 29dB, the average was at 39dB, and the maximum was at 63 dB. The maximum noise level only dropped by 5dB, while the average dropped by an impressive 19 dB. This is more than expected, and it’s great news because it’s where most of the printing time is. Overall, the results were satisfactory, and the printer is now more stable and quieter.

Paving Slab

I went to my nearby DIY shop and got a garden paving slab. Although it’s a standard grey one and not very attractive, it serves its purpose. I lifted my printer, placed the slab on the ground, and then put the printer back on top of it. I hope that the mass of the slab will absorb any vibrations that are not absorbed by the printer’s feet.

Paving Slab Results

Upon analyzing the data, I noticed that the results were exactly as expected. There was minimal change in the minimum and average values, but there was a significant drop in the maximum dBs.

The reason behind this anomaly is that louder noises are caused by big mechanical movements that are usually fast. These vibrations flow through the feet but get absorbed by the massive mass of the paving slab, resulting in lower maximum dBs. The data shows that the minimum dB value was 27, the average dB value was 34, and the maximum dB value was 53.

Styrene Foam

I had some pieces of Styrene Foam lying around, which is a type of plastic commonly used in modeling and crafting. I was considering ways to utilize it and thought about placing it under the paving slab. The idea was that it might help improve the insulation of the slab. I wasn’t sure if it would make any difference, but I figured it couldn’t hurt to try. So I went ahead and placed the foam under the slab, making sure it was evenly distributed. After that, I decided to test the quality of my 3D printer by printing a calibration cube. Overall, I was curious about the results of my experiment and eager to see if there would be any noticeable change in the insulation of the paving slab.

Styrene Foam Results

I didn’t notice much of a difference in noise levels after making the change. I didn’t expect much since most vibrations should have been stopped by the foot modification and the paving slab. But it doesn’t hurt to try, right? Here are the noise levels before and after the change:

• Minimum: 26 dB
• Average: 34 dB
• Maximum: 52 dB

While it was still a positive change, I don’t think I’ll be keeping this modification because it makes the printer taller and looks janky. The small improvement in noise levels doesn’t justify the awkward appearance. Additionally, I know that over time, the styrene will break down and leave little balls everywhere, which will be annoying.

Conclusion

The experiment has been a resounding success. I have made significant modifications to the Prusa Mini, which now sits on top of a paving slab supported by modified shock-absorbing feet and foam. The test results leave no doubt that substantial gains have been achieved. The foam added no value, and it will be removed shortly. The printer’s noise levels have significantly reduced due to the modifications, making it much easier to work in the same room without any distractions. Any remaining noise is not overly aggressive and can be easily drowned out by other ambient noises.

In the coming year, I plan to undertake another project to build an enclosure for the printer. The primary aim of this project is to enable the printing of exotic materials. Additionally, the enclosure should help reduce the printer’s noise levels further. I am confident that this project will be successful, and a new sound test will be conducted once it is completed.

Overall, I assert that the modifications made to the printer have substantially improved its performance and noise levels. I am eager to continue enhancing the printer’s capabilities in the future.