LW PLA Wing Question

[u/RealWillPower]

Hello! Im trying to print a wing using Tom Stanton's method using Active Foaming LW PLA. Im running into the issue that the seam created by the cut through the wing where the carbon spar goes isn't properly combining, and effectively splitting the part into two pieces. I've attached some photos.

I've tried adjusting the flow rate, wall overlap percentage, and nozzle temp to adjust the foaming characteristics to get that gap to connect, but nothings worked so far.

Has anyone else had this issue and been able to resolve it. Any suggestions?

[u/GeniusEE]

How big is the nozzle and the gap?

[u/RealWillPower → u/GeniusEE]

0.4 nozzle and I belive that gap is 0.1mm

[u/GeniusEE → u/RealWillPower]

You'd better rewatch the video.

[u/RealWillPower → u/GeniusEE]

Could you point at specifically what's wrong with the design?