Holes, Gaps or Bumps in the Top Surface
Holes and bumps on a flat top happen because the first top layers have to bridge across the gaps in the infill, and some lines sag. Add top layers (or raise the top shell thickness) first, then raise infill density or switch to a pattern that supports the top more evenly. If lines still do not join, check cooling and flow.
A flat top surface has small dips, holes or puffy bumps, often in a pattern that matches the infill below, and sometimes you can see the infill lines through the surface. Polymaker notes it is most common on large flat areas. A different pattern, where every top line is thin and there are gaps between all of them, points to under-extrusion instead.
first
Open the slicer preview and step through the top layers. Count the solid layers above the infill and look at how far the first one has to bridge between infill lines. Then look closely at the defect: if the holes and bumps follow the infill pattern, it is pillowing and the fix is more top layers or more infill. If the lines are thin and separated everywhere, including on walls, it is flow, and changing layer counts will not help.
Likely causes, most common first
- Too few top layers for the layer heightMost common
Prusa suggests at least 3 top layers and notes thin layers need more: its example uses 9 top layers at 0.1 mm against 3 at 0.3 mm Starting point. Polymaker says too few layers leave the sagging first layer uncovered. - Infill too sparse under the topVery common
Prusa explains top solid infill bridges over the infill, and lower infill means longer bridges and more sag. Polymaker calls raising infill usually the next most effective change for severe pillowing, after top thickness. - Infill pattern with long open gapsCommon
Polymaker notes grid and rectilinear can leave long straight gaps under large tops, while gyroid and similar patterns support more evenly. - Weak bridging from material or coolingCommon
Polymaker explains that ABS, ASA and some nylons print with little fan and so bridge poorly, needing more infill and top layers than PLA. - Under-extrusion or flow set lowOccasional
Starved lines cannot close the surface however many layers you add. The OrcaSlicer calibration guide places flow ratio calibration after temperature, max volumetric speed and pressure advance. See Under-Extrusion. - Holes around features rising through the topLess common
OrcaSlicer's surface expansion setting exists to fill the gaps left where a feature rises up through a top surface.
Fix it, one change at a time
- Add top layers. Raise the top layer count or the top shell thickness. Polymaker suggests at least 4 to 6 times the layer height of top thickness Rule of thumb, for example 5 to 6 layers at 0.2 mm. In OrcaSlicer, the shell thickness setting adds layers automatically when the layer count alone would be too thin.
- Raise infill density. Polymaker suggests roughly 15 to 30% for normal parts Rule of thumb, and more for very wide flat tops. Prusa offers a modifier that raises infill only in the layers just under the top, which saves material on big parts.
- Switch infill pattern to gyroid or another pattern without long straight gaps, and preview again.
- Check cooling for the top layers. For PLA, make sure the part fan is running. For low-fan materials, slow the top layers and rely on more infill and more top layers.
- Calibrate flow if the lines are thin everywhere, following the calibration order in Flow Calibration.
- For holes around raised features, use surface expansion if your slicer has it (OrcaSlicer releases after 2.4.2).
- Change one thing at a time and keep the rest fixed, so you know which change worked.
Confirm it is fixed
Print a flat test plate the size of your real top surface, as Polymaker suggests, first with your current settings and then with the changes. The top should be continuous, with no pits or infill showing when viewed under a raking light. Then use the same settings on the real part.
the extruder clicks, grinds or skips while printing top layers, or the nozzle drags through and tears the top surface. Those are extrusion or collision faults, not layer settings; see Nozzle Hitting the Print and the printer maker's guide.
Why it happens
Infill is mostly air. When the slicer starts the solid top, the first top layer has to bridge from one infill line to the next, and over each gap the line sags a little. The second layer lands on a slightly uneven surface and partly fills it in, the third smooths it further, and so on. Pillowing is what you see when there are not enough layers to cover the sag of the first one, or when the gaps are so wide that it sagged too far to recover.
That gives three levers, in order of effect: more top layers to cover the sag, more or better-distributed infill to shorten the gaps, and better cooling so each bridged line sags less. Layer height matters because the count of top layers is what covers the sag; Prusa's advice that thin layers need more top layers is about keeping the total thickness up.
Thin, separated lines on every surface are a different problem: there is not enough plastic, whatever the layout. Fix flow first in that case. For what each top and bottom setting does, see Top and Bottom Layers, and for the infill side, Infill Patterns and Density.
- Pillowed/Pitted Top of Print Polymaker
- Layers and perimeters Prusa Research
- Top and bottom shells OrcaSlicer Wiki
- Calibration Guide OrcaSlicer Wiki
Last reviewed 2026-11-05