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makrspacr
(@makrspacr)
Trusted Member
Poor Quality prints suddenly

Recently my printer started making noise when running fast, and in the areas of the print where the noise is occuring, I am getting poor quality prints. The top z surface in those areas becomes bumpy, it sounds almost like it's the nozzle hitting the print.  I am printing with Jesse PLA in Design White.

The print I have been working on has an elliptical shape, and it happens mostly at the two narrow ends of this ellipse. Those locations correlate with the points where the printer head is slowing and reversing in Y, and moving the fastest in X.

I have a ticket open with PRUSA. They've had me inspect the X/Y rods and lubricate them. It certainly helped, but the problem did not go away. Here are pics of a print before the lubrication being done:

 

I did print a EM vase mode part to check my flow settings, and that part came out perfectly, so perhaps there is a combination of HW issue and my settings which causes this issue, which results in a hardware noise and over extrusion bumps. This is my main issue, but I also have some layer shifting bugs as the print gets taller:

Ideas to check?

Posted : 14/07/2024 12:14 pm
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

A bit more info. Here's a comparison between the stock 0.2mm speed settings, and my print settings.

 

The only filament setting I changed was EM to 1.098 based on my test prints.

The print settings are default other than having the actual printer details added so I can print directly from the slicer or my web browser rather than having to print via USB stick.

 

Posted : 14/07/2024 12:41 pm
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

One other update...

I have my filaments in a dry box with 6 spools above my printer. I have not had it setup for too long, and had some issues with filament getting off the spool, and stuck between spools in the past. And this print was using #2 spool, which is a bit off to the side and I have some concern the bend radius of the teflon tube might cause variations in feed tension.

For my last test print of the part in question, I removed the spool from the box, and used the default setup on top of the printer. It had the same issues. So I have confirmed that's not a contributor, and I can also confirm my filament is dry.

Posted : 14/07/2024 12:50 pm
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

Another update. I am thinking there's something going on with the print head, not X/Y axes. When I touch my finger on the X/Y motors and rails during printing, I don't feel anything unusual. When I lightly touch the extruder print head I feel more vibration. I also noticed if I lightly touch the side of the print head, near the lower X support rail, I also feel a vibration. This makes me feel something is going on in the extruder that is the issue.

I've decided to try a different filament too. I have a Jessie Limer Green so I'm running through calibration. My test prints show a bumpy pattern on the top surface. But the side walls look good, no obvious issues. Here is a pic of the surface quality of the top layer:

The side walls on this print (vase mode) look good, there are no major issues like in my other printed parts.

Posted : 14/07/2024 2:10 pm
fabnavigator
(@fabnavigator)
Estimable Member
RE: Poor Quality prints suddenly

It would be interesting to try it w/o the input shaper.

Posted : 14/07/2024 2:11 pm
makrspacr liked
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

Green filament test results. Results are worse, I've adjusted some settings and I had delamination between layers for the first time.  It get worse as the layers add up. The initial layers seemed great.

 

Pictures:

 

VIDEO:

IMG_1274

 

Next I'll try without Input Shaping.

Posted : 14/07/2024 4:14 pm
fabnavigator
(@fabnavigator)
Estimable Member
RE: Poor Quality prints suddenly

I'm willing to try to print your model on my MK4 if you can get me the STL file.

Posted : 14/07/2024 4:31 pm
Antimix
(@antimix)
Reputable Member
RE: Poor Quality prints suddenly

WOW 😲 ,  this seems the same issue another user is suddenly experience: Bad printing - No answers from PRUSA SS
Looking at the picture the aspect seems the same. On his printer the issue started suddenly, then was apparently solved, and then it come back again.
I tried to figure what it can be, but seem a mix of issues (e.g. mechanical, electrical)

 

 

Posted : 14/07/2024 7:21 pm
Eef
 Eef
(@eef)
Reputable Member
RE: Poor Quality prints suddenly

Just another view: (based on experience 😉 ) 
lubricate the partfan(s) on the printhead. These are cheap fans, and they vibrate more and more. 
I swapped the fan for a new fan (€ 4,- per fan) and much better now. less noice and smoother results. 
(I thought of this, because that fan comes in after 5 layers or so . 

We will do what we have always done. We will find hope in the impossible.

Posted : 14/07/2024 7:48 pm
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

Printing without input shaper was much improved, though not as good as previous prints prior to this issue arising. I'll add pics later.  Thanks for the other suggestions, I'll check into them.

Posted : 16/07/2024 1:46 am
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

Here are some pics of what I'd call defects and poor quality with input shaper turned off. The noise I heard while printing basically went away, and I did not get the overextrusions and bumpy surfaces on the tops of the layers early on.

 

Posted : 16/07/2024 11:35 am
Diem
 Diem
(@diem)
Illustrious Member

It's not obvious from the pictures; how did you support those flexing structures while printing?  Did you slow the print to damp flexing?  If not, try again at 75% speed.

What is the green filament?  The white PLA is another poor choice for quality checking, it's always a difficult pigment.

Please show us the issue on a simpler print, these inherently tricky shapes make diagnosis difficult.

Cheerio,

Posted : 16/07/2024 12:34 pm
Antimix
(@antimix)
Reputable Member
RE: Poor Quality prints suddenly

@makrspacr

- Are you using the Legacy Nozzle Adapter ? 😏 

Posted : 16/07/2024 8:02 pm
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

The comments about the fan had me inspecting the extruder assembly, and the vibration at the lower x rail got me thinking perhaps I should check the fasteners for something loose. I found most of the screws which were accessible on the extruder head had become loose. Tightened all of them up and it's back running well. I still hear some vibration, so I probably should do this on the entire machine. I wish they provided torque guidance for the assembly kits.

 

Thanks for all the tips!

Posted : 17/07/2024 1:49 pm
Antimix
(@antimix)
Reputable Member
RE: Poor Quality prints suddenly

- Did you swapped the nozzle recently just before the issue appeared ?

BR

Posted : 17/07/2024 5:48 pm
Antimix
(@antimix)
Reputable Member
RE: Poor Quality prints suddenly

Looking at your print artifacts, I start suspecting the Nextruder is moving slightly during the print.

Can you ensure the 3 green screw are tighten and the 3 yellow supports are tighten also ?

BR

Posted : 17/07/2024 5:57 pm
makrspacr liked
Diem
 Diem
(@diem)
Illustrious Member

More likely those strappy parts are flexing under nozzle pressure.

Cheerio,

Posted : 17/07/2024 8:01 pm
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

Where are those standoffs?

Posted : 28/07/2024 2:33 pm
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

Printed other parts that are more solid, and having similarly bad results. And I've printed this part with excellent results in the past.

Posted : 28/07/2024 2:33 pm
makrspacr
(@makrspacr)
Trusted Member
Topic starter answered:
RE: Poor Quality prints suddenly

No nozzle swaps - original one.

Posted : 28/07/2024 2:34 pm
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