Simplify3D Dual Extrusion Setup: Multi-Color, Soluble Supports, and Ooze Control

Simplify3D Dual Extrusion Setup: Multi-Color, Soluble Supports, and Ooze Control

I've configured dual extrusion setups in Simplify3D for multi-color prints, soluble support workflows, and multi-material parts. The software offers two distinct approaches — the Dual Extrusion Wizard for multi-model prints and per-feature extruder assignment for single-model prints — and understanding when to use each is key to successful dual extrusion printing.

Two Approaches to Dual Extrusion

Approach 1: Dual Extrusion Wizard (Multiple Models)

Use this when you want to print two different models in different colors:

1. Import both models into Simplify3D
2. Go to Tools → Dual Extrusion Wizard
3. Assign each model to a different extruder
4. The wizard creates separate processes for each model

Approach 2: Per-Feature Extruder Assignment (Single Model)

Use this when you want different extruders for different parts of a single model (e.g., soluble supports):

1. Open Edit Process Settings
2. Set Auto-Configure Extruders to "Both Extruders"
3. Assign extruders to specific features in the Layer, Additions, Infill, and Support tabs

Simplify3D's documentation explains: "This workflow is different from the Dual Extrusion Wizard, as it only requires one Process."

Setting Up Per-Feature Extruder Assignment

Step 1: Configure Auto-Settings

1. Click Edit Process Settings
2. Set Auto-Configure Extruders to "Both Extruders"
3. Select the appropriate material combination in Auto-Configure for Material (e.g., PLA + PVA)
4. This ensures both extruders are heated and primed at the start

Step 2: Assign Extruders to Features

Click Show Advanced to see all tabs, then assign extruders:

Layer tab:

• Primary Extruder: Used for perimeters and outer solid layers
• Infill Extruder: Used for internal infill

Additions tab:

• Skirt Extruder
• Prime Pillar Extruder
• Raft Extruder
• Ooze Shield Extruder

Infill tab:

• Infill Extruder: Can be different from the primary extruder

Support tab:

• Support Extruder: Which extruder prints support structures
• Dense Support Extruder: Which extruder prints dense support layers

Step 3: Print

Click Prepare to Print and the software generates G-code that switches between extruders as needed.

Ooze Control

When printing with two extruders, the inactive extruder continues to ooze filament while the other is printing. Simplify3D offers two tools to manage this:

Prime Pillar

• Prints a small solid pillar at the start of each layer
• The inactive extruder extrudes material onto the prime pillar before switching to the active print
• This purges any oozed filament and ensures clean extrusion when the extruder activates
• Enable in the Additions tab

Ooze Shield

• Prints a thin shell around the entire model
• The inactive extruder deposits oozed filament onto the shield instead of the model
• The shield is removed after printing
• Enable in the Additions tab
• Particularly useful for models with complex geometry where the prime pillar alone isn't sufficient

Multi-Color Printing with the Dual Extrusion Wizard

Step 1: Import Models

1. Import the first model (e.g., a logo's base)
2. Import the second model (e.g., the logo's text)
3. Position them so they align in the 3D view

Step 2: Run the Wizard

1. Go to Tools → Dual Extrusion Wizard
2. Select the first model and assign it to Extruder 1
3. Select the second model and assign it to Extruder 2
4. The wizard creates two processes, one for each model/extruder

Step 3: Configure Settings

1. Double-click each process to edit settings
2. Set the correct temperature for each material
3. Enable prime pillar or ooze shield in the Additions tab
4. Click Prepare to Print and select all processes

Printing with 3+ Extruders

For printers with three or more extruders:

1. Create a separate process for each extruder
2. For each process:
   • Click Select Models to choose which models use this process
   • Set Auto-Configure Extruders to "All Extruders"
   • Set the Primary Extruder in the Layer tab
   • Set the Infill Extruder in the Infill tab
   • Set the Support Extruder in the Support tab
3. Click Prepare to Print and select all processes

Common Dual Extrusion Issues

Warning: Process Not Configured for Number of Extruders

Simplify3D's forum explains: "This warning is generally caused by having the Auto-Configure for Extruder choice set to a single extruder instead of the 'Both Extruders' pre-configuration."

Fix: Change Auto-Configure Extruders to "Both Extruders" (or "All Extruders" for 3+).

Colors Bleed into Each Other

• Enable Prime Pillar to purge the inactive extruder
• Enable Ooze Shield to catch oozing filament
• Increase the Wipe Shield Distance from the part
• Reduce nozzle temperature slightly to reduce oozing

Soluble Supports Don't Dissolve Cleanly

• Ensure the support extruder temperature matches the soluble material's requirements
• PVA typically prints at 180-200°C; HIPS at 230-240°C
• Check that the support infill isn't too dense (10-20% is usually sufficient)
• Increase Horizontal Offset to 0.1mm for better separation

Nozzle Collision During Extruder Switch

• Check that the G-Code tab includes proper tool change commands
• Verify the printer's firmware supports the T0/T1 tool change commands
• Add a Z-lift before tool changes in the G-Code tab

Material Combinations

Common dual extrusion material combinations in Simplify3D:

| Primary | Support | Notes | |---------|---------|-------| | PLA | PVA | Water-soluble, most popular combination | | PLA | HIPS | Dissolved in limonene, cheaper than PVA | | ABS | HIPS | Both dissolve in limonene | | PETG | PVA | Water-soluble supports for PETG parts | | PLA | PLA (different color) | Multi-color prints, same material |

Summary

Simplify3D offers two dual extrusion workflows: the Dual Extrusion Wizard for multi-model multi-color prints, and per-feature extruder assignment for single-model prints with soluble supports. For soluble supports, set Auto-Configure Extruders to "Both Extruders", then assign the support extruder in the Support tab. Always enable prime pillar and/or ooze shield to manage oozing from the inactive extruder. The most common issue — the "process not configured" warning — is fixed by changing the Auto-Configure Extruders setting from single to "Both Extruders". For multi-color prints, use the Dual Extrusion Wizard to assign each model to a different extruder, then select all processes when preparing to print.

Dual extrusion adds complexity but enables capabilities impossible with single extrusion: water-soluble supports for complex geometry, multi-color prints for prototypes and educational models, and multi-material parts combining rigid and flexible filaments. The key to success is managing the inactive extruder — without prime pillar or ooze shield, oozing filament contaminates the print. Start with a simple two-color test print before attempting complex multi-material parts, and always verify that both extruder temperatures are correct for the chosen material combination.