Extruder clicks and stops
It's been months of me working on this issue. I did some early trouble shooting and decided that the hot end was the problem. I replaced the original with a Revo Six. The issue persisted.
If I print hot and slow I can get a short print out with minimal issues, but it's hardly the quality I'm used to from Prusa.
Most of the time I can clear it with a cold pull and the printer behaves "normal" for a little, the extruder immediately comes back to life. Occasionally the extruder gear appears to be so stuck it requires a little push for it to continue. This made me think there was something blocking it but I've cleared everything possible nearby.
Heat creep was an option I looked into, but I don't think that's it as I can touch the top of the heat break right before the issue happens (its room temp) and the extruder motor doesn't get crazy hot.
- Performed general maintenance - https://help.prusa3d.com/article/i3-printer-regular-maintenance_2072
- Extruder fan cleaned and orientation verified
- Idler tension played with from minimum to maximum
- Heatsink is clean (its new!)
- PTFE is newly cut and set all the way in
- Started using thermal paste on the screw end of the Revo nozzle
- Extrusion multiplier played with all the way down to 0.9, calculated at .96
- Happens with both PLA and PETG
- Lots of cold pulls and use of cleaning filament
- Disassembled extruder again to verify extruder motor spins freely, cleaned the gears and lubed the gear end (not the filament teeth)
- Verified the set screw on the gear is tight and lined up correctly, redid this a couple times
- Trimmed the top of the PTFE even further just in case it was blocking
- Verified cables are routed correctly, redid some routing but nothing was rubbing
- Reset printer and re-updated to latest official Revo firmware
What else can I try? I'm worried it's the extruder motor itself but that doesn't make much sense. I'm so tired of trouble shooting this issue and I just want my printer to work again.
Best Answer by Diem:
It might also grip, slip and click if the gears were worn so that as the pressure rises the grip fails - I'm not saying this *is* the problem, I'm suggesting it as a candidate to rule out.
How many hours has the machine printed?
If you have been using filled filaments in a 0.4 nozzle (0.6 is the generally suggested minimum) there might be an exotic clog left in there - remove the nozzle and check the path is open, try a different nozzle in case nozzle wear has partially closed it.
Clicking suggests an imbalance between the internal pressures and the extruder forces, not often a motor issue - it *might* be a failed bearing.
You may do better to contact Prusa Support.
Cheerio,
Have you been printing a lot of abrasive filament? If so examine the edges of the Bondtech gears and check they are not worn.
Extruder clicking is usually an idler tension issue but can be triggered by partial clogs or filament inclusions - eg., woodfill or glassfill with a small nozzle.
Cheerio,
RE:
Impressive observation! I was using a woodfill with a .2 nozzle and it created some issues before I realized my mistake and have only used it on the .4 nozzle since. But now the .4 nozzle won't act normal on even my 'easiest' PLA.
I've repeatedly cleaned the hotend; cleaning filament + cold pulls, lots of them! How else can I clean out any clogs/issues?
Do I have to pull out the PTFE tube again and make sure there's nothing stuck under it?
I can buy new gears, but damn they're expensive...
I can buy new gears, but damn they're expensive...
First take a look at the gripping teeth, use a lens. Check for wear.
Cheerio,
RE: Extruder clicks and stops
Took a macro pic of the teeth; the focus is right between the two gears.
This is after I cleaned them up with a wire brush. Still some rust but the teeth appear in tact. It's hard for me to tell - are these so worn I need new gears?
I might be willing to get new gears, maybe even a new extruder motor, but if this doesn't fix the issue I'm just gonna lose it!
Sorry, that picture isn't clear enough to be certain.
You are looking for sharp gripping edges.
Cheerio,
RE: Extruder clicks and stops
But if the edges weren't gripping the extruder motor would slip, like when the idle tension is too low. Right?
Instead it's gripping fine as it clicks when it cant push more in instead of slipping, and stops eventually after enough clicking.
I don't want to spend $50 on gears for nothing!
It might also grip, slip and click if the gears were worn so that as the pressure rises the grip fails - I'm not saying this *is* the problem, I'm suggesting it as a candidate to rule out.
How many hours has the machine printed?
If you have been using filled filaments in a 0.4 nozzle (0.6 is the generally suggested minimum) there might be an exotic clog left in there - remove the nozzle and check the path is open, try a different nozzle in case nozzle wear has partially closed it.
Clicking suggests an imbalance between the internal pressures and the extruder forces, not often a motor issue - it *might* be a failed bearing.
You may do better to contact Prusa Support.
Cheerio,
RE: Extruder clicks and stops
Thank you for trying Diem! I really appreciate the support. Prusa Support suggested I lower my retraction settings which I'll try, but had nothing else to offer.
Unfortunately at this point all I can do is sell it (with a huge asterisk about the issue) and get a Bambu printer... I'm just so tired.