Prusa XL Crashes If Stopped Mid Print & Then Tool Parked that is Not Tool 1.
 
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Prusa XL Crashes If Stopped Mid Print & Then Tool Parked that is Not Tool 1.  

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Wolfy
(@wolfy)
Active Member
Prusa XL Crashes If Stopped Mid Print & Then Tool Parked that is Not Tool 1.
  • Prusa XL 5 Head
  • Firmware =6.2.5+8912 (latest available as of April 28, 2025)
  • PETG filament is loaded in tool #1 and tool #5

 

Steps to recreate the bug:

  1. Start a print job.
  2. Stop the print job in mid-print when tool #5 is actively being used
  3. At this point the printer moves tool #5 to the rear left, in front of tool #1.
  4. On the printer Control screen, instruct the printer to park the current tool.
  5. At this point the printer starts a homing sequence and one of the first things it does is move the Y axis towards the rear of the printer.  Since tool #5 is still in the tool changer, tool #5 crashes into tool #1, which is parked.

This is reproducible 100% of the time.

Also note, one time when tool #5 crashed into tool #1, the printer operating system completely crashed and my printer lost its entire configuration, forcing me to go through the entire printer re-calibration (~1 hour).

The suggested fix is, if a print is stopped mid-print, either don't move the print head so close to tool #1, or park the current tool before moving the tool changer in front of tool #1.  If the tool changer doesn't have a tool attached to it, then it won't crash into tool #1.

 

Posted : 23/05/2025 1:45 pm
1 people liked
Wolfy
(@wolfy)
Active Member
Topic starter answered:
RE: Prusa XL Crashes If Stopped Mid Print & Then Tool Parked that is Not Tool 1.

Also posted on github:  https://github.com/prusa3d/Prusa-Firmware-Buddy/issues/4662

Posted : 24/05/2025 12:22 am
Wolfy
(@wolfy)
Active Member
Topic starter answered:
RE: Prusa XL Crashes If Stopped Mid Print & Then Tool Parked that is Not Tool 1.

I contacted Prusa via chat today to get an update on this bug.  Their response was:  "we don't have any news still. I will double-check it with XL-specialists and let you know per email later. So for now no precise information yet."    I hope Prusa XL doesn't get left behind with the release of Core 1.

Posted : 09/09/2025 2:56 pm
Wolfy
(@wolfy)
Active Member
Topic starter answered:
RE: Prusa XL Crashes If Stopped Mid Print & Then Tool Parked that is Not Tool 1.

Prusa support asked me to make a video demonstrating the problem. I will not do that because I don't want to damage the machine and don't want to waste another hour re-calibrating everything after the crash happens. Plus, it has been easily reproduced 100% of the time by many users. If the Prusa firmware developers would just take some time to even try and reproduce the problem themselves, I'm convinced it could be easily fixed.

Posted : 09/09/2025 4:16 pm
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