Mid print - extruder moves to extreme right
The printer is 2 weeks old, and has been printing perfectly. All of a sudden, mid-print, it decides to move the extruder to the right. On a large print, it moved approx 4cm to the right. (The photo with the blue print .... you can see a line in the print where it has moved to the right.)
On a smaller print it moved the extruder completely to the right. (White print). This causes the extruder to knock against the z axis frame and crash.
The zero point now seems to be where the extruder ended up.
I have completed a complete XYZ calibration and the "wizard" several times. The same thing keeps happening.
It is not the print file, as the same file printed perfectly the day before.
Any suggestions on a) what caused this to occur? and b) what I can do to correct this issue?
I am using Prusa PLA on a textured sheet.
RE: Mid print - extruder moves to extreme right
Helps if you say pre-built or constructed from a kit. Home builders are likely to make mistakes not found in a pre-built.
I will start by assuming your X axis is binding.
Turn power off and move extruder all the way from one side to the other.
Does it move smoothly both directions? Can any cables hit the extruder? Does the cable bundle come straight out of the extruder with no sharp flexing?
If you feel any binding, try loosening the 5 screws in the back of the extruder that hold the bearing. If they are too tight, they can cause this.
And while you are poking around in there - consider giving the bearings a proper greasing.
RE: Mid print - extruder moves to extreme right
There is a firmware bug that if the filament sensor is enabled the printer can lose its brains. Disable the filament sensor and see if your prints behave.
That said, the image shows a more typical friction problem where the printer stalls. If crash detection is enabled, you can see what the last print reported. If there is a crash, then friction is very likely to blame - or a cat attacked the printer while it was moving.
RE: Mid print - extruder moves to extreme right
I had something similar happen when a firmware update went wrong. I reverted to an older version and it fixed the problem. Try re-flashing the firmware and see if that helps.
RE: Mid print - extruder moves to extreme right
@mdaneman - what you describe is often caused not by the firmware, but by folk not performing a full reset with data clear after flashing a new rev. Loading the new firmware these days almost always requires the reset so old data doesn't corrupt new data.
RE: Mid print - extruder moves to extreme right
Is reset with data clear required after a firmware upgrade? Is that documented anywhere by Prusa? Just following their instructions, it seems that you should be able to just flash and go. This worked for me upgrading from 3.7.x to 3.8.0. If you really lose your calibration anytime you upgrade firmware that would be a royal pain in the ass. I would consider that a bug.
RE: Mid print - extruder moves to extreme right
What you find in this forum is users with experience.
Most times it conforms to Prusa recommendations. Some times it does not.
Washing textured build plates with Dawn and water is one. That is a Prusa Not Recommended - but it is still necessary.
If they tell you to clear EEprom storage after a flash - there is a good reason for it.
RE: Mid print - extruder moves to extreme right
I've been hosed by firmware updates too many times to count, and erasing the EEPROM data is the fix. Prusa may not have a written recomendation to do the clear, but they also say they ship prelubricated linear bearings. YMMV
RE: Mid print - extruder moves to extreme right
Thank-you everyone for your suggestions.
The printer is built from kit and has completed almost 50 hours of printing.
I had done a firmware update (approx 10 days ago) and so did a complete reset with clearing data. (Not sure how this is any different from running the wizard as that also clears the data.)
Also lubricated all the bearings and smooth rods, gave all the fixings a tighten in case they had loosened in the first couple of weeks of use, and then loosened the 5 screws in the back of the extruder that hold the bearing.
Have since completed two very small prints .... and both have printed successfully!
Thanks again for all the advice!
RE: Mid print - extruder moves to extreme right
Congratulations!
Your primary test for bearing problems is power off sliding the extruder on the X Axis both directions, feeling for binding.
Same for the Y axis. They should both be smooth.
May you print long and prosper.