When processing parts for sparse fill interior build style, slightly sloping part
geometry’s that are created with an air gap between the outer contour and the
rest of the part cause the outer contour to not attach to the rest of the part or
“delaminate”. Sometimes repositioning the part will eliminate this problem, or there
is a method to correct the air gap using the custom groups feature in Insight.

Creating A Sparse Fill

STEP 1: After slicing, building supports, and creating toolpaths, inspect the slice file
              layers to look for the air gap (figure 1).

It is best to view each layer in shaded mode to detect the air gap.

STEP 2: If, after inspecting the slice file, detect the air gap between inner and outer  
              walls of the part, it may be possible to correct the problem by rotating the
              part. If the geometry of the part allows an orientation that eliminates the
              sloped surface from the z-plane, then rotating the part will correct the
              problem. Figure 1 was rotated 90 degrees along the y-axis, then reprocessed
              (sliced, build supports, create toolpaths, figure 2).

              In some cases it may be necessary to incrementally rotate the part in X or Y                   by several degrees even though it may create a rough bottom and/or top                       surface because it will no longer lay flat (figure 3)

For more information, download the full best practices document here.

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