What problem can arise from having wall thickness that is too thick in FDM prints?

Having wall thickness that is too thick in Fused Deposition Modelling prints can indeed generate excessive internal stress within the printed object. This phenomenon occurs because the material expands during the printing process and subsequently contracts as it cools. When the walls are significantly thicker than required, the interior layers may cool at different rates compared to the outer layers, leading to uneven cooling and internal stress. This accumulated stress can ultimately manifest as cracks or warping in the final product, potentially compromising the item’s structural integrity and functionality.

While longer print times or uneven color might be considered issues tied to thick walls, they do not directly correlate to the mechanical stresses and structural concerns that arise specifically from excessive thickness. Similarly, a porous texture typically relates to issues with material flow or extrusion settings rather than simply the thickness of walls. Thus, the presence of thick walls can lead to a build-up of internal pressure that adversely affects the overall durability of the FDM print.