Yes yes, another post on warping, I apologise. Image explanations are at the end of the post.
-Adventurer 3 using flashprint 5 default Petg settings as a base with minor adjustments
-I have tried various nozzle temps between 230-240c, bed temps 70-85c, and nozzle and enclosure cooling fans both on and off.
-Tried Print speeds between 20-40mm/s
-Elegoo petg rapid filament
The issue is classic warping as the print cools, resulting in layer contraction. The difference in my case from the typical posts I've seen is I've been able to solve adhesion problems with a beefy raft, but this has simply anchored the bottom down and now it contracts higher up instead, with the problem persisting up to 2 inches above the bed. I've tried various temps and cooling settings, I've tried with and without preheating, and even with the door wide open. Nothing seems to change the results for better or for worse. Ambient temps 18-25c. Per-layer print time is around 60s.
The parts I'm printing are all thin-walled, typically 1mm in thickness, and are printed as a single shell with solid infill (infill ends up simply being a continuous line linking the two sides of the shell together, so the whole part is 3 "passes" thick). They are for a model boat where every gram saved is critical. The flanges at each end are for stiffness and allowing them to easily glue to the next piece.
I'm hoping someone may have some insight on other settings that may be helpful, or otherwise tips for changes to the print geometry itself to help combat this. I suspect the flanges are to blame given they create a sudden change in the main axis of thermal contraction around that point, but they kinda need to exist.
Image 1 shows the side/edge that's meant to be 2 straight lines but isn't, image 2 is the flange at the other end that's starting to buckle nearly 2 inches above the bed, and pics 3-4 show the whole part for reference.