6.2.2 Firmware for Original Prusa XL  

RE: 6.2.2 Firmware for Original Prusa XL

since updating to this i have a lot of stringing and the print quality has gone bad on multicoloured prints, its the same files i used before updating, i have went back to previous firmware and its perfect again so something wrong in the new firmware causing all this stringing

RISPONDI: 6.2.2 Firmware for Original Prusa XL

Hi, I also did the latest update and I started having problems with the laiers moving that I had never had, the printer would not reattach the tool anymore...How do you load the old firmware?

RE: 6.2.2 Firmware for Original Prusa XL

Posted by: @widget2k13

since updating to this i have a lot of stringing and the print quality has gone bad on multicoloured prints, its the same files i used before updating, i have went back to previous firmware and its perfect again so something wrong in the new firmware causing all this stringing

Can you put it on GitHub.  They won't see it here. 

RE: 6.2.2 Firmware for Original Prusa XL

wow. not touching this with a 10 foot pole....

i had to check my XL is still on 6.2.0-alpha2 Firmware for Original Prusa XL i've had it crash over and over and it does layer shift when you have certain settings in the slicer or the way a STL is placed on the bed, however it was reasonably stable, between the USB issues and bricking my XL over and over when i went for the newest firmware i'm not playing this game anymore. until i start seeing posts praising some new firmware its not worth being the alpha tester any more. from 2023 this machine has been a disaster. and i paid for mine in 2020 or 2021 i don't even remember any more. the last great machine prusa made was the MK2S then they gave up or something. i can't recommend a new prusa to anybody in 2025 they need to stop releasing new machines with even more issues and start going back and fixing everything even back to the MK3 machines. then with each generation they move away from open source and crowd sourcing...... urg.... so frustrating...

RE: 6.2.2 Firmware for Original Prusa XL

What exactly are the symptoms of the layer shift issue?   I have a brand new XL 5 Head that I've setup.   Three test prints of the benchy on the usb drive have failed when I've used fw 6.2.2 and succeeded using the 6.1.3 version that came on the usb drive.   For the 6.2.2 attempts, the first had a distinct xy shift about 1/3 the way and other two had issues printing the roof in exactly the same place.  The roof issue is the only one that repeated and at first glance doesn't seem like an offset issue but it happened in the same way in the same location on two different prints.  I can collect and send more information if that helps.  Attached a pic of the 2nd attempt result.

I'm obviously sticking with fw 6.1.3 since I've got to get this printer going but can spare time to help.  The new filament management capabilities of the newer rev are very nice.

RE: 6.2.2 Firmware for Original Prusa XL

I don't know if anyone has been able to correlate the exact conditions that cause it.

it seems random because you can have 2 STLS with the same slicer program one will layer shift and one will not.

there is also a question if the layer shift is an issue with the really bad firmware code in managing information coming over USB drive or wifi as it could be part of the same issue with the microcontroller being unable to keep up with the information it needs to pull into the memory buffer and still handling all the other house keeping it needs to do to keep the printer running.

the number of tool heads does not seem to matter since you can run in single tool mode and still have the layer shifting occur.

it is more like a race condition where information comes in at a certain time and causes a mistake and that causes the layer shift as GCODE has been corrupted and the machine did not catch it.

I can tell you i had less issue with the alpha firmware 6.2 as going to the newer firmware instantly causes red screen crashes claiming my USB was defective which is it not.

you may find some STL causes a layer shift and just by moving it on the bed to a different location the layer shift disappears or the layer shift moves up or down to a different area.

it is quite frustrating and unpredictable.

you may also find you go several stl shapes and never run into an issue then suddenly the machine is red screening or skipping layers or layer shifting.

what i noticed was some slicer settings with changing perimeters to print first or some  alignment of seams made it occur more often.

earlier slicer versions going back before they added that stupid swirl when retracting i guess before  slicer 2.5 seem to have less issues in causing the shift but they have all kinds of issues with the XL and print quality.

now i have also seen layer shifting occur more frequently on the MK3S+ i have with never slicer versions. it got the point where i basically went back to my MK2S machines when i need a mission critical print and i don't need the size of the XL.

its been a super frustrating 2 years of this now and its getting old. the updates are muddled and confused and its obvious prusa pulled resources needed to maintain current products to throw into newer untested equipment like the Core One.
this is because the Chinese Junk that has been around for years and copied the early days of prusa are now surpassing them on all fronts.

the short of this is there is no real way to predict when the shift will happen you can kind of give yourself better odds of it not happening often with slicer versions and firmware versions but it can still happen and moving things around might help it but you might find a situation where you have failed 10 prints in a row and then you might need to use an alternative machine or slicer to make it work. 

the XL still has major issues with the driver that controls the USB drive, the WIFI control is a disaster as well.
so that is the state of things in 2025 so far.

RE:

I bought this beast because I thought that it was well received and based on my personal experience with my MK3S and Mini which are beasts in their own way.  I did have confidence that any initial kinks would be worked out by now.  Yikes...   

@juancholo:    Thank you for your comprehensive information.  I notice that you don't specifically mention input shaping.  Is that because it's been eliminated as a possible cause?   I wonder the same thing about bgcode vs gcode formats.

I've seen a suggestion that using the ethernet port might get around the possible bottle neck issues with USB and wifi.  Does anyone have any insight on this?   I don't have drops in my work area at this time but that can be addressed if getting hardwired connections in there is a way to help the firmware manage data buffering.  

Does anyone have a part they can share that consistently reproduces the problem without hours of print time?   My testing so far was with the BonkersBenchy.bgcode on the usb drive.  I thought that using a distributed file would eliminate software issues so just the hardware is being checked out but doesn't seem to be working out.   It would be interesting to have a model that I can put in the slicer and produce 4 versions using combinations of gcode file type and input shaping enabled or not.  Unless of course this has all been done; I know that I'm late to the party and apologize if these approaches have been tried already. 

Anyone from prusa dev monitoring this thread?  Got any test models?

I've seen a suggestion that using the ethernet port might get around the possible bottle neck issues with USB and wifi.

USB and sneakernet will always be best.  Unless your access point is mounted on the ceiling or high on a rear wall the signal is bound to be blocked from time to time by moving metal.  If network access is essential it's better to run cat6 cable.

 

My testing so far was with the BonkersBenchy.bgcode on the usb drive

The Bonkers Benchy is not a test file, it's a party trick; I wish Prusa had never included it.  The regular Benchy *is* a test file and a picture of one can tell us a lot about printing issues.

Anyone from prusa dev monitoring this thread?

Very unlikely. This is a user <> user forum.

Cheerio,

RE: 6.2.2 Firmware for Original Prusa XL

HI EVERYONE, I SOLVED ALL THE PROBLEMS I TELLED YOU BY REMAKING THE SLICE WITHOUT IS

RE: 6.2.2 Firmware for Original Prusa XL

I've have layer shift with or without the input shaper.

basically my theory is the machine becomes overwhelmed by the required timing of events, it has to monitor all the temperatures and sensors run error checks,

and has to load information from the usb within a small window of timing, if a garbage collection occurs when critical reading is required from the USB then it seems to skip information, the input is expected to be in a certain order and if information is skipped then the nozzle position basically goes into LALA land.

that would explain the shifting and also why if you move something around on the bed the skip may not occur because the timing has changed.

layer shifts also seem to occur more frequently the larger the STL is which makes sense if a larger STL is on the bed then this is even less free time occurring for a critical read to occur from either network or USB or wifi device.

i think that some slicer settings can make it worse because it would make the required Gcode longer in places.

really there needs to be some kind of checksum that the XL will do after reading information in to make sure it matches what is suppose to be there.

if a checksum is failed it should re-read the USB and check again. but it just reads, errors and continues on like nothing happened and you get a skip or layershift.

there is really nothing to be done since its all in the firmware that needs to be gone over but prusa took all the resources away to constantly churn out new products equally buggy. 

the issue is fixable but looking at prusa overall it will never be fixed they know the XL is old tech and they need to jump past what Bambu just put out, so they will hock as many XLs for 4,000$ as possible knowing there is a large failure rate and that customers complain but enough get sold they don't care.

they never fixed things going back to the MK2 machines that they promised,, the MK3 series machines were a disaster they basically said were done and jumped to the MK4 machines. now they are jumping to core one.

prusa wants and needs to expand as fast as possible to keep up with china but it isn't happening. 

they now traded how stable a product can be for pushing out as many machines as possible to stay profitable.

the result is more and more people realized they got scammed on a good name that now makes a terriable product and eventually enough people will go elsewhere.

in the early days with less competition prusa could maintain. but today 3d printing is going mainstream and everyone is now trying to put out machines with even better quality because the market is flooded with good parts. they are paying better and going to a closed source rather then open source software.

prusa has been going more and more closed source for a while its getting harder to get manuals and documentation on purpose.

we are coming out of the golden days of 3d printing, its now going commercial and getting locked down.

as far as these forums are concern Prusa will very rarely officially come on here and make a statement about anything.

these forums were basically designed for the customers to help each other and sometimes it would trickle out into some official fix.

the last time that happened was first few weeks of the MK3 machine release where they had a major bug with the PINDA and live Z calibration was almost impossible.

that bricked my MK3 machine for almost 4 months the first time.

as for my XL... when it works it is great compared to the MMU version. however in 2 years of ownership now since 2023 the first 6 months the machine was basically unusable. the next 6 months were ok the quality was ok not great still lots of ringing. then they started more and more "features"(bugs) with the slicer and trying to cram more things without vetting them properly as the MK4 came out. next begin maddening firmware bugs making the machines unable again unless you reverted firmware and slicers to try and get something that was stable-ish. its now 4 months into 2025 and i had to leave my machine in a late 2024 configuration because otherwise the XL just crashes and red screens all the time...

its at a point you should not update your slicer nor update firmware if you have a machine that is working, first check online here or REDDIT and see what other people are going through.

RE: 6.2.2 Firmware for Original Prusa XL

A quick update to share where I'm at: Have had no more issues with w 6.1.3 with simple geometry and single material using slicer 2.9.1, USB, bgcode, and IS.   I did have successful multi-material prints using the included BonkersBenchy which was made with slicer 2.7.4.   I will be moving to multi-material jobs that I slice myself in the next week. 

I'm offering to help do any "guided" field testing if prusa needs some help validating improvements if the tests are reasonable run time for throw away parts. The newer firmware had some nice features that would be great to have available moving forward.