Single Tool XL Prints Fail, Error Message is Gcode Instruction too Long for Buffer

ogauger — Tue, 14 Apr 2026 16:24:09 +0000

I'm having a very frustrating problem with my XL. I slice a model wth Prusa Slicer and try to print it on the XL using Prusament PLA (via the USB stick). The same model, depending on the alignment of the stars, can result in a gcode file that prints fine, OR a gcode file where the print fails with the error message that the XL encountered a Gcode instruction too long for the buffer. Generally, that results in a skipped layer, which ruins the print and wastes the filament. I tried Prusa support, and the tech who answered was of absolutely no help and then ghosted me. Anyone else have this problem and, if so, how did you solve it?

Just to add, if the stars align for Prusa Slicer to slice a gcode file that prints without error, that same file can be counted on to print without error. Often, if I tweak the model slightly and re-slice, it will result in a gcode file that won't print successfullly.

Any help or suggestions greatly appreciated! My XL is air-gapped, so there is no direct comms between the computer (or network) and the XL. All data transfer is done through the flash stick.

Sam

Single Tool XL Prints Fail, Error Message is Gcode Instruction too Long for Buffer - Hardware, firmware and software help

Single Tool XL Prints Fail, Error Message is Gcode Instruction too Long for Buffer