Very inconsistent first layer causing adhesions issues, nozzle contact with part, layer shifts, and rough top layers.
Hello,
Been running the Prusa Mini+ for a couple years now and have started to run into some issues. I am on the latest firmware with Input Shaping using prusament pla and the associated profile in prusa slicer (.2 structural speed)
1. I can hear the nozzle contacting the print.
2. Very rough top surface finishes as a result of nozzle contact.
3. Sometimes the nozzle will hit hard enough to cause a layer shift by physically moving the spring steel plate.
4. Very inconsistent first layer is probably the root issue but i have been unable to tune it on the calibration. see photos lines change width throughout the calibration print. ALL OF THE LINES IN THE PHOTO WERE TAKEN WITH THE SAME Z OFFSET. I did not change the offset mid calibration.
Trying to figure out whats going on with the printer.
Perhaps the pinda is failling? That could explain why the first layer is so inconsistent. But i do see the z stepper moving up and down during the calibration print.
Maybe the IS firmware itself is causing inconsistent extrusion thus pushing too much or too little plastic? Perhaps i should roll back to an earlier firmware without IS?
Any other thoughts?
Thanks.
RE: Very inconsistent first layer causing adhesions issues, nozzle contact with part, layer shifts, and rough top layers.
check the insides of the Bowden tube between the extruder and the print head, if the inside is oval then it needs to be replaced.
See https://forum.prusa3d.com/forum/assembly-and-first-prints-troubleshooting/solution-sofar-for-inconsistent-under-extrusion-and-excessive-stringing-after-a-few-years-of-printing-replace-your-bowden-tubes/
See my GitHub and printables.com for some 3d stuff that you may like.
RE: Very inconsistent first layer causing adhesions issues, nozzle contact with part, layer shifts, and rough top layers.
It's odd that you're having warpage in the middle of the sheet according to your line thickness. Make sure the actual heatbed is clean, as well as the underside of your print sheet -- things like crumbs and debris can cause all sorts of issues.
The majority of the problems will stem from the fact that it's only a 4x4 grid that's probed for the bed mesh, and the PINDA probe is offset from where the nozzle actually contacts. From my experience, I've had issues with the right edge specifically, but nothing too severe that it can't be corrected using the Mesh Bed Correction feature (under the control menu).