Consistent layer shifts using FW 6.2.2  

RE: Consistent layer shifts using FW 6.2.2

Update: 

 Going back to 6.1.3 did not resolve the issue. 

Reducing the travel max acceleration value did not resolve the issue. 

There is no collison, and the issue seems to happen during layer change. 

This is almost acting like the issues I had at one point with another brand printer when writing to the USB for power recovery. Any help would be greatly appreciated here. I bought this printer just for this project and this is getting very frustrating. 

RE: Consistent layer shifts using FW 6.2.2

There's still a bug in the firmware causing layer shifts with gyroid infill, so if you use gyroid, it might be worth checking if switching to a different infill pattern helps.

RE: Consistent layer shifts using FW 6.2.2

Interesting,  I do happen to be using gyroid as that is what the airframe design needs. That being said I did try a few more trouble shooting ideas and got some positive progress.

1-Changed out the USB to a Sandisk with no change

2-Tried cloud based download vs prusa link vs direct download, no change

3-Disabled everything I could to reduce memory useage, no change

4-marked the pulleys/belt to determine if it was a stepper missing a step, or belt slippage. Verified that slippage was not happeneing. 

5-Slowed the travel speed down to 200, and the travel acceleration to 3000, This seems to eliminate the layer shift, but I am curious if I am just masking a motion control bug? 

Thank you!!

-Aaron

RE: Consistent layer shifts using FW 6.2.2

I'm also having issues with my 5 head XL, but only when printing specifiek parts. My issues may be slightly different than your issues, but maybe my experience helps with analyzing these kind of issues.

In my case I'm trying to print a part using Extrudr PETG which has minor overhang (it's a mask, egg shaped at the top) and it kept failing at a certain point, even though I tried 3 different print heads, nozzle temperatures (temp tower filament tuning), support types and orienting the part in a slightly different way. Symptoms here are visible layer shifts, minor spaghetti strings, and some collision sound during (infill) printing. It took 5 hours printing to get to the part where the issues occur. After 5 failed full test prints, I ended up reducing test time by splitting the object and only printing the area that fails, this also excludes that the issue is only caused at a certain printing height.

I found out that I was able to print the test slice correctly with Prusmant PLA. On the test slice part I have fixed my issues by 'removing' infill by using 6 vertical shells perimeters. This is acceptable for my print as it is a mask and there barely is any infill anyways, only at a few spots where the mask is a little bit thicker. I'm now running the full part print again to see if it works for the entire print.

I have the feeling that these kind of printers have a hard time printing parts for which they need to extrude extremely short pieces of filament, like sometimes happens with small infill areas, because they can cause little imperfections/bumps, causing the nozzle to hit it causing layer shifts.

RE: Consistent layer shifts using FW 6.2.2

Just following up on this issue. Since lowering my travel speed and acceleration, I have had around 150 hours of trouble free printing with various materials/ parts/ and settings. Prints are beautiful and the machine has been rock solid. 

RE: Consistent layer shifts using FW 6.2.2

I've had multiple failures while trying to print some static mixers we've designed for a piece of equipment. Tried many different orientations, etc. and thought the majority of failures were due to design issues, etc. Now, after the Buddy3d camera recent updates I was able to do a time lapse... after reviewing the stills I see the layer shift happen. I made some changes to the layout (moved it on the build plate) and reprinted... Layer shift again, at the same spot (within a layer or two).

Just found this thread and hoping that slowing down these, and other settings, will fix the issue because it's getting expensive having failures... with $200/750g roll of filament (PVDF).

I'll follow up if this fixes the layer shifting.

Prebuilt XL 5 Tool with current fW (6.2.5+8192), and official Prusa enclosure.

RE: Consistent layer shifts using FW 6.2.2

Update

Slowing the travel speed and travel acceleration down as suggested seems to have fixed the layer shift, at least on the last print that was giving me issues. I was able to successfully print, twice, the static mixers... which previously would have issues due to layer shifting.

I also read that activating Steeper Ramp could help, depending on the reason for the layer shift. I've added that to my profiles and will see how it goes. 

RE: Consistent layer shifts using FW 6.2.2

I too have layer shifting problems and have had success with lowering the travel speed and acceleration. I tried the suggested changes on previously failed projects in Prusa Slicer and Orca Slicer and so far the prints have worked. I'd like to note that I have not changed any other settings. Still using gyroid infill, same print objects, same print material. This has worked on prints up to 328mm so far. 

• Printer: XL 5TFirmware: 6.2.5+8912
• Infill: Gyroid
• Filament profile: Prusament PETG
• New Travel Speed: 200
• New Travel Acceleration: 3000

I'd love to hear if anything else helps or improves things.