Bizarre Print Fail Later in Print
Recently, after moving a printer from my office to my home and back I've been encountering a bizarre print issue where prints fail in the near left corner and left side generally. This breakdown occurs after a flawless first layer, and sometimes many layers after that.
I've run all the calibrations several times, I got one print out nice, but 3/4 have failed.
Please help me if you can, I have a deadline Friday and I have several 24hr prints left in it.
Also, I know the speeds are a bit fast and the layer heights are tall (using 6mm nozzle), but I've had a lot of good prints with this profile before the move.
Here's the GCODE
; generated by Slic3r 1.33.8-prusa3d-win64 on 2017-04-03 at 18:10:08
; external perimeters extrusion width = 0.67mm
; perimeters extrusion width = 0.67mm
; infill extrusion width = 0.73mm
; solid infill extrusion width = 0.67mm
; top infill extrusion width = 0.67mm
M107
M115 U3.0.10 ; tell printer latest fw version
M83 ; extruder relative mode
M104 S230 ; set extruder temp
M140 S85 ; set bed temp
M190 S85 ; wait for bed temp
M109 S230 ; wait for extruder temp
G28 W ; home all without mesh bed level
G80 ; mesh bed leveling
G1 Y-3.0 F1000.0 ; go outside pritn area
G1 X60.0 E9.0 F1000.0 ; intro line
G1 X100.0 E12.5 F1000.0 ; intro line
G21 ; set units to millimeters
G90 ; use absolute coordinates
M83 ; use relative distances for extrusion
G1 E-0.80000 F2100.00000
G1 Z0.350 F7200.000
G1 X58.289 Y85.728 F7200.000
G1 E0.80000 F2100.00000
M204 S1000
G1 F3000
.............................................................................
M107
G4 ; wait
M104 S0 ; turn off temperature
M140 S0 ; turn off heatbed
M107 ; turn off fan
G1 X0 Y200; home X axis
M84 ; disable motors
; filament used = 60804.7mm (146.3cm3)
; total filament cost = 0.0
; avoid_crossing_perimeters = 0
; bed_shape = 0x0,250x0,250x210,0x210
; bed_temperature = 90
; before_layer_gcode =
; bridge_acceleration = 1000
; bridge_fan_speed = 50
; brim_width = 0
; complete_objects = 0
; cooling = 1
; default_acceleration = 1000
; disable_fan_first_layers = 3
; duplicate_distance = 6
; end_gcode = G4 ; wait\nM104 S0 ; turn off temperature\nM140 S0 ; turn off heatbed\nM107 ; turn off fan\nG1 X0 Y200; home X axis\nM84 ; disable motors
; extruder_clearance_height = 20
; extruder_clearance_radius = 20
; extruder_offset = 0x0
; extrusion_axis = E
; extrusion_multiplier = 1
; fan_always_on = 1
; fan_below_layer_time = 20
; filament_colour = #B5F5FD
; filament_cost = 0
; filament_density = 0
; filament_diameter = 1.75
; filament_max_volumetric_speed = 0
; filament_notes = "List of manufacturers tested with standart PET print settings for MK2:\n\nE3D Edge\nFillamentum CPE GH100\nPlasty Mladeč PETG"
; first_layer_acceleration = 1000
; first_layer_bed_temperature = 85
; first_layer_extrusion_width = 0.65
; first_layer_speed = 50
; first_layer_temperature = 230
; gcode_arcs = 0
; gcode_comments = 0
; gcode_flavor = reprap
; infill_acceleration = 2000
; infill_first = 0
; layer_gcode =
; max_fan_speed = 50
; max_layer_height = 0.25
; max_print_speed = 100
; max_volumetric_extrusion_rate_slope_negative = 0
; max_volumetric_extrusion_rate_slope_positive = 0
; max_volumetric_speed = 0
; min_fan_speed = 30
; min_layer_height = 0.07
; min_print_speed = 5
; min_skirt_length = 4
; notes =
; nozzle_diameter = 0.6
; only_retract_when_crossing_perimeters = 0
; ooze_prevention = 0
; output_filename_format = [input_filename_base].gcode
; perimeter_acceleration = 800
; post_process =
; pressure_advance = 0
; resolution = 0
; retract_before_travel = 1
; retract_layer_change = 1
; retract_length = 0.8
; retract_length_toolchange = 3
; retract_lift = 0.5
; retract_lift_above = 1
; retract_lift_below = 199
; retract_restart_extra = 0
; retract_restart_extra_toolchange = 0
; retract_speed = 35
; skirt_distance = 2
; skirt_height = 1
; skirts = 0
; slowdown_below_layer_time = 15
; spiral_vase = 0
; standby_temperature_delta = -5
; start_gcode = M115 U3.0.10 ; tell printer latest fw version\nM83 ; extruder relative mode\nM104 S[first_layer_temperature] ; set extruder temp\nM140 S[first_layer_bed_temperature] ; set bed temp\nM190 S[first_layer_bed_temperature] ; wait for bed temp\nM109 S[first_layer_temperature] ; wait for extruder temp\nG28 W ; home all without mesh bed level\nG80 ; mesh bed leveling\nG1 Y-3.0 F1000.0 ; go outside pritn area\nG1 X60.0 E9.0 F1000.0 ; intro line\nG1 X100.0 E12.5 F1000.0 ; intro line
; temperature = 240
; threads = 4
; toolchange_gcode =
; travel_speed = 120
; use_firmware_retraction = 0
; use_relative_e_distances = 1
; use_volumetric_e = 0
; variable_layer_height = 1
; wipe = 1
; z_offset = 0
; clip_multipart_objects = 0
; dont_support_bridges = 1
; extrusion_width = 0.67
; first_layer_height = 0.35
; infill_only_where_needed = 0
; interface_shells = 0
; layer_height = 0.45
; raft_layers = 0
; seam_position = nearest
; support_material = 0
; support_material_angle = 0
; support_material_buildplate_only = 0
; support_material_contact_distance = 0.1
; support_material_enforce_layers = 0
; support_material_extruder = 1
; support_material_extrusion_width = 0.35
; support_material_interface_contact_loops = 0
; support_material_interface_extruder = 1
; support_material_interface_layers = 0
; support_material_interface_spacing = 0
; support_material_interface_speed = 100%
; support_material_pattern = rectilinear
; support_material_spacing = 1.5
; support_material_speed = 50
; support_material_synchronize_layers = 0
; support_material_threshold = 40
; support_material_with_sheath = 0
; support_material_xy_spacing = 50%
; xy_size_compensation = 0
; bottom_solid_layers = 5
; bridge_flow_ratio = 0.95
; bridge_speed = 20
; ensure_vertical_shell_thickness = 1
; external_fill_pattern = rectilinear
; external_perimeter_extrusion_width = 0.67
; external_perimeter_speed = 30
; external_perimeters_first = 0
; extra_perimeters = 1
; fill_angle = 45
; fill_density = 20%
; fill_pattern = cubic
; gap_fill_speed = 40
; infill_every_layers = 1
; infill_extruder = 1
; infill_extrusion_width = 0.73
; infill_overlap = 25%
; infill_speed = 50
; overhangs = 0
; perimeter_extruder = 1
; perimeter_extrusion_width = 0.67
; perimeter_speed = 40
; perimeters = 2
; small_perimeter_speed = 20
; solid_infill_below_area = 0
; solid_infill_every_layers = 0
; solid_infill_extruder = 1
; solid_infill_extrusion_width = 0.67
; solid_infill_speed = 40
; thin_walls = 0
; top_infill_extrusion_width = 0.67
; top_solid_infill_speed = 20
; top_solid_layers = 6
Re: Bizarre Print Fail Later in Print
Why is this still happening?!?!?! I did everything customer support said and more, short of rolling back the firmware. What the hell?
Re: Bizarre Print Fail Later in Print
You certainly titled the thread correctly.. Bizarre.
You might get better diagnosis with more information.
1) What is the filament? Chemical and brand.
2). Extruded and bed temps?
3). What is the room temp? Drafts? Dry or humid?
4). What is your layer height, and other slicer settings? Fill type and percent? Skirt?
5). What slicer? What source for .stl file? What rev of firmwere?
6). Assume other prints are fine? Any this tall? Or all shorter?
7). Does it always unravel at the same height? Other models succeed at this height?
I am looking to remove variable by variable.
Can you get close ups of the failed area?
Any advices given are offered in good faith. It is your responsibility to ensure that by following my advice you do not suffer or cause injury, damage or loss. If you solve your problem, please post the solution…
Re: Bizarre Print Fail Later in Print
What size nozzle?
Is it free of clogs?
Might it be dusty? Filter the filament in foam.
What is your flow set to?
Any advices given are offered in good faith. It is your responsibility to ensure that by following my advice you do not suffer or cause injury, damage or loss. If you solve your problem, please post the solution…
Re: Bizarre Print Fail Later in Print
To me, it looks like there is no filament being output when the extruder is towards the left of the build platform, there are total areas with no filament,
this could be due to a deteriorating cable assembly perhaps on the extruder motor. any one of the four wires could stop extrusion.
regards Joan
I try to make safe suggestions,You should understand the context and ensure you are happy that they are safe before attempting to apply my suggestions, what you do, is YOUR responsibility. Location Halifax UK
Re: Bizarre Print Fail Later in Print
Thanks for responding, here are the answers to your questions.
You certainly titled the thread correctly.. Bizarre.
You might get better diagnosis with more information.
1) What is the filament? Chemical and brand.
A: Esun PETG, my favorite, usually prints flawlessly
2). Extruded and bed temps?
A: Extruder 240, Bed 90
3). What is the room temp? Drafts? Dry or humid?
A: Enclosed print chamber, no drafts, dry (I haven't measured the air temps, but the problem occurs with the chamber door open or closed)
4). What is your layer height, and other slicer settings? Fill type and percent? Skirt?
In the G-code, but the basics are height : 0.45mm, Nozzle: 0.6mm, Fill: Cubic 20%, Skirt: Nope
5). What slicer? What source for .stl file? What rev of firmwere?
Latest official Prusa Slicer and Firmware. STL is self generated in MAYA.
6). Assume other prints are fine? Any this tall? Or all shorter?
The exact same print succeeded days before.
7). Does it always unravel at the same height? Other models succeed at this height?
It has issues at different heights for different prints, some models started failing on layer 2, some failed several inches up.
I am looking to remove variable by variable.
Can you get close ups of the failed area?
Re: Bizarre Print Fail Later in Print
I bet the cable harness is hitting the print, try fixing it with zip ties.
Re: Bizarre Print Fail Later in Print
Okay, let's take a divide and decide methodology.
Print and printer worked well before, but extrusion is stopping intermittently (but in similar locations).
Two sources for that, mechanical and electrical. Below I will try to list all the ways I can come up with that could cause that, no matter how unlikely. You can eliminate them one by one with test or checks, and hopefully find it. Maybe others will see a method I do not.
Mechanical:
- Clogged nozzle
- Feed mechanism slipping (tension on load springs or pulley not attached to stepper or pulley teeth stripped.)
- Kink in feed real binding (not free to feed filament) or bad entry angle to extruder (gets worse as it gets higher and to sides)
- Filament is wildly out of spec in parts, getting to thin and not feeding.
- Water in filament creating temporary bubbles in extruder.
Electrical: (At extruder, in cable (splices), or at RAMBO)
- Intermittent connection on stepper wires
- Intermittent connection on heat element (heat drops below good flow)
Does that help give you things to go check out? Please post success or failure for the rest of us to learn from.
Any advices given are offered in good faith. It is your responsibility to ensure that by following my advice you do not suffer or cause injury, damage or loss. If you solve your problem, please post the solution…
Re: Bizarre Print Fail Later in Print
So I spent last night taking apart the frame and meticulously reassembling it. I got a perfect calibration for the first time (instead of slightly skewed like it was before). Now that corner is worse off than ever, it even fails during the V2 calibration.
I tried flashing back to the two previous firmware iterations, and the print still fails.
I also removed the print bed and placed it on a flat surface, I couldn't visibly identify any deformations in the board.
I also took this video of the feeder when it messes up, I notice that it slows down near the front left corner and even reverses direction (stutters) a couple times on the last two lines near that corner... I'm starting to wonder if the issue is with the auto calibration thinking that part of the board needs less flow (if that's even how it works, in addition to nozzle position) and it's moving into negative extrusion? Or is that just stupid?
Anyways here's a link to the videos of the feeder stuttering in that corner (It's in the front left corner so you can skip through the start.)
https://www.dropbox.com/s/otrg1irgf68ikqb/2017-04-07%2003.14.31.mp4?dl=0
https://www.dropbox.com/s/a6vk73e4q97w6x9/2017-04-07%2003.39.46.mp4?dl=0
Thank you so much to anyone still helping me. It's super frustrating.
Re: Bizarre Print Fail Later in Print
Oh, I also ran a bunch of the esun cleaner filament and didn't detect any debris on the ejected material...
Re: Bizarre Print Fail Later in Print
My guess is you're losing on of the electrical connections to the stepper motor. Exacerbated when in the left front corner.
Check plugs are firm.
Remove filament.
Run some long extrusion commands and wriggle the wire bundle. If it judders again this would confirm it.
It doesn't look like slippage because you can normal hear that.
Re: Bizarre Print Fail Later in Print
I agree. That looks like bad stepper motor wiring, but it is strange that it happens in the front right, because as far as the extruder knows there is only left and right - the front to back is only part of the y-axis which moves under the extruder.
Maybe somehow the heat bed cabling is moving the extruder cabling creating that intermittent connection.
I would open the electronics box, and disconnect and then reconnect the extruder stepper connection, and make sure there is appropriate strain release on that cable.
Look for interactions between those two wire bundles in the left front and see if you can make it do that with a long extrusion command.
I can't think of any way the Y would affect the stepper lines except interference with the bed.
I don't believe the calibration adjust flow, and it would not make the stepper go back steps like that. That seems like one line has a loose connection.
Good luck!
Any advices given are offered in good faith. It is your responsibility to ensure that by following my advice you do not suffer or cause injury, damage or loss. If you solve your problem, please post the solution…
Re: Bizarre Print Fail Later in Print
My guess is you're losing on of the electrical connections to the stepper motor. Exacerbated when in the left front corner.
Check plugs are firm.
Remove filament.
Run some long extrusion commands and wriggle the wire bundle. If it judders again this would confirm it.
It doesn't look like slippage because you can normal hear that.
Wow, nailed it. I moved the extruder to the problem position on the board, ran the load filament script and moved the cable bundle up about an inch and got repeatable stutters. Now the question is how do I fix it?
Video of experiment below:
https://www.dropbox.com/s/iconi5h9g6s4tvj/2017-04-07%2022.18.35.mp4?dl=0
Re: Bizarre Print Fail Later in Print
I agree. That looks like bad stepper motor wiring, but it is strange that it happens in the front right, because as far as the extruder knows there is only left and right - the front to back is only part of the y-axis which moves under the extruder.
Looks exactly right, you posted right when I was typing that, but thank you as well, you raised this as a possibility earlier, I was still working through your suggestions when Andrew replied.
I have already re-seated the extruder into the rambo (as per your previous suggestion), could it be a possibility that the issue is further down the line. I'm just wondering on what the next step is, should I just disassemble the whole extruder and look for frayed/compressed cabling?
Re: Bizarre Print Fail Later in Print
I have already re-seated the extruder into the rambo (as per your previous suggestion), could it be a possibility that the issue is further down the line. I'm just wondering on what the next step is, should I just disassemble the whole extruder and look for frayed/compressed cabling?
Most failures in the cable bundle happen directly behind the extruder assembly where all the cables come together. I had a pinda probe and extruder fan both get broken wires in that spot. I have since printed the new MK2S parts which is a better design.
You should be able to narrow your search for the damaged cable to about a 3-4" area. Once found you should be able to solder the wires back together and seal up with shrink wrap.
Re: Bizarre Print Fail Later in Print
See this thread: http://shop.prusa3d.com/forum/improvements-f14/cable-management-for-mk2s-t3680.html
You could also print out the new MK2S parts.
Re: Bizarre Print Fail Later in Print
Trying not to speak too soon, but I cut out the part of the extruder cables that looked like they were causing the problem and soldiered them together. After putting them back on my calibration layer was flawless. First things I'll be printing are the new electronics enclosure and the new extruder assembly to hopefully help prevent this from happening again.
Thank you everyone for your help! 😀