PLEASE HELP: After print failure all new prints have major layer adhesion issues, parts delaminate with little effort.
Let me start to let you know I have been using Prusa printers since the Mk2 was released. I also introduced 3D printing to our factory to make tools and fixtures. While I do not consider myself an expert, I am certainly not a beginner. Probably have printed 1000 parts or so. The printer literally paid for itself on the first print job. Prusa makes a terrific product, that's why I recommended we use these in our factory and for anyone who wants a 3D printer at home.
In the factory we only use ProtoPasta conductive PLA to eliminate ESD damage from charged plastic to our products.
Typically the parts we print are used as mechanical fixtures so 3~4 layers top, 3~5 outlines and 40~60% fill, this makes nice sturdy parts.
Last week I started a 6hr print job in the evening and came back to find the print failed. Unfortunately my coworkers reset the printer to turn off the buzzer, they said the screen indicated the printer detected the filament was out. But this I3Mk2S machine does not have filament detection so I don't exactly know what happened.
I found the nozzle was completely clogged, the ProtoPasta conductive PLA has a tendency to "chalk up" or the plastic turns to a powder like material when heated a long time. So I cleaned the nozzle using a heat source in addition I did 4~5 cold pulls.
Other observations:
- After cleaning loading filament resulted in audible skips in the extender gears (still clogged???)
- The filament was changed to a new roll, same exact issue
- printing the same .gcode on our MK3 works with NO issue
- no change in printing profile on PrusaSlicer
- tested using Simplify3d, same poor results
I tried to print a new part and it appears to be OK but the layers do not appear to be bonding very well at all.
Each layer can easily be removed almost layer by layer. To minimize warp I use a tall skirt, even this is not bonding and was the likely cause of a layer shift the last debug print.
Normally the parts we get are very robust, 21mm x 50mm x 150mm. All parts printed now can easily be twisted and de-laminated with vert little force. Before good parts are very stiff and cannot be twisted.
Any ideas what is wrong?
Thanks in advance!
-jim
RE: PLEASE HELP: After print failure all new prints have major layer adhesion issues, parts delaminate with little effort.
Forgot to mention, have been using Prusament PLA 0.35 FAST settings to print the Protopasta PLA.
RE: PLEASE HELP: After print failure all new prints have major layer adhesion issues, parts delaminate with little effort.
Hi,
I would try to run the self-test first, then xyz-calibration, after that temperature-calibration to sort out the problems. If nothing of that procedures helps, I would change the ptfe-tube of the coldend...perhaps it have degenerate over time and block your filament.
Hopefully, something helps
RE: PLEASE HELP: After print failure all new prints have major layer adhesion issues, parts delaminate with little effort.
Thanks for the suggestion. I had already run self-test first and xyz-calibration. Now running temp cal.
I printed a simple 10mm x 24mm x 120 block. Prints perfect, no layer separation, very strong.
So I printed one more of the parts I was having a problem with (4hr print). Same issue so there is a print time / heat component to this issue maybe?
Sliced with simplify 3d with supports for a small overhang that runs the length of the part. Some of the supports printed and bonded to each other while the rest were unconnected strings of filament??? This time the part is much stonger
Guess I need to look into the PTFE tube next.
RE: PLEASE HELP: After print failure all new prints have major layer adhesion issues, parts delaminate with little effort.
This might be a cooling issue - check the fans, their alignment and the state of the shroud.
Cheerio,
RE: PLEASE HELP: After print failure all new prints have major layer adhesion issues, parts delaminate with little effort.
Tanks again for the tips.
The fans appear to be working noramally but I'll certainly take a closer look.
This machine has the Noctua fan upgrade I installed well over a year ago.
As soon as I find my PTFE tube spare will tear down the cold / hot end to see what I find.
- jim
RE: PLEASE HELP: After print failure all new prints have major layer adhesion issues, parts delaminate with little effort.
More details regarding I3 mk2 printer:
Performed PENDA cal / heat up. No improvement.
While printing some new parts and still have issues (I have NOT changed the PTFE tube yet).
See attached, results of cancelled print due to terrible fill. This is NOT consistent!! Sometimes the first layer is perfect and this condition occurs seemingly random on other layers making the part very weak.
We have 2 Prusa printers so I printed the same part / file on the MK3, printed perfectly. Please see attached photo.
Any ideas?
Thanks in advance