Filament 'stuck', but not really after latest 6.4.0
 
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Filament 'stuck', but not really after latest 6.4.0  

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Danut Tabacaru
(@danut-tabacaru)
Member
Filament 'stuck', but not really after latest 6.4.0

Hi All,

The latest firmware introduced this auto retract feature.

Seemed weird to me at first, and still not sure if I want it enabled by default, but i left it on to see if how I'd feel about it after some time.

However, ever since it starting doing this maneuver , occasionally (maybe 1/5 prints) will report 'filament stuck' right after the print starts and the first line is extruded to prime the extruder.

The filament is NOT stuck... I simply click on unload/load and it loads it automatically without me doing anything. It was clearly not stuck because it extruded that first line without issue...

Seems like a firmware issue?

Posted : 10/12/2025 4:59 pm
LarGriff
(@largriff)
Reputable Member
RE:

https://forum.prusa3d.com/forum/postid/773033/
This problem, and others, with firmware version 6.4.0. has been reported by numerous people.  Most have reverted to firmware 6.2.6.  Prusa is not what it used to be.

This post was modified 1 month ago by LarGriff

MK4S/MMU3

Posted : 11/12/2025 2:12 pm
Danut Tabacaru
(@danut-tabacaru)
Member
Topic starter answered:
RE: Filament 'stuck', but not really after latest 6.4.0

Thanks for the reply, I didn't know it was so wide-spread (I tried a search but nothing showed up).

From quickly browsing the thread, I am a bit relieved that others have the same issue (so likely not a hardware fault on my end).

I have also run into the issue you mentioned - waiting for reloading filament mid print. I have had this issue before with older firmwares, but the issue manifested itself exactly 2 times in an entire year. On 6.4.0, this same reload filament issue happened to me twice on the same print! (I ended up abandoning that print.)

I am unsure if I will revert back to an older FW version just yet.

From reading the thread you linked, I have a feeling the bugs are to do some incompatibilities with saved configurations from older firmwares.

I re-did my filament sensor calibration like 3 times (it seemed flaky, occasionally not detecting the filament) and for now... everything seems to be back to working order in 6.4.0. (I am expecting another issue to show up eventually though)

Posted : 11/12/2025 4:28 pm
Danut Tabacaru
(@danut-tabacaru)
Member
Topic starter answered:
RE: Filament 'stuck', but not really after latest 6.4.0

Well, filament sensor re-calibration did not fix the issue.

I even cleaned out the entire gearbox assembly, and still, I get "stuck filament" after the first line for priming the extruder.

I'm back on 6.2.6 until it gets fixed.

Posted : 11/12/2025 11:06 pm
dracolorium
(@dracolorium)
Active Member
RE: Filament 'stuck', but not really after latest 6.4.0

 

Posted by: @danut-tabacaru

Well, filament sensor re-calibration did not fix the issue.

I even cleaned out the entire gearbox assembly, and still, I get "stuck filament" after the first line for priming the extruder.

I'm back on 6.2.6 until it gets fixed.

That's exactly the same behaviour we had with our four printers. The message appeared after the purge line. Always. Since we went back to 6.2.6, everything has been working perfectly again.

Posted : 12/12/2025 7:43 am
Petr
 Petr
(@petr-10)
Member
RE: Filament 'stuck', but not really after latest 6.4.0

Same problem with both MK4S I have, it started in RC version, just hit reset and start print again, you do not need to unload and load. It seems like bug, I revert back to lower FW too.

Posted : 20/12/2025 11:21 am
quazimoto
(@quazimoto)
Member
RE: Filament 'stuck', but not really after latest 6.4.0

This happens on every print for me on my MK3.9s. It's never had a filament jam before, but after 6.4.0 it's happening all the time. I thought the filament retractions was a pretty cool idea to stop oozing, but it looks like just retracts way too far and it oozes out of the nozzle anyway, so not sure what the purpose of this is. Anyways, reverted to 6.2.6.

Posted : 12/01/2026 5:24 am
up_and_adam
(@up_and_adam)
Member
RE: Filament 'stuck', but not really after latest 6.4.0

I'm seeing the same thing; first time I saw it was loading PLA after having printed PETG, so I thought it was struggling to purge the PETG at PLA temperatures and just needed more purging, but I've seen it in several prints now.  I guess it's time to learn how to downgrade firmware, on my brand new machine.  What an excellent experience this thousand dollar printer has been so far, there was definitely a reason to pay 3 times what a Bambu costs for this.

Posted : 20/01/2026 2:48 am
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