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Philippe BAUER
(@philippe-bauer)
Eminent Member
XL firmware 6.4.0 alpha

The alpha 6.4.0 firmware causes big head crash. Also it not possible to make the printer quiet, the phase stepping motor calibration  doesn't work properly. As a result i have reloaded the 6.2.6 

Posted : 29/09/2025 6:46 pm
1 people liked
FoxRun3D
(@foxrun3d)
Illustrious Member
RE: XL firmware 6.4.0 alpha

Known issue. Several issues related to head crash logged on Github. Why they didn't detect that before releasing the firmware is beyond me.

Formerly known on this forum as @fuchsr -- https://foxrun3d.com/

Posted : 30/09/2025 1:43 pm
1 people liked
Philippe BAUER
(@philippe-bauer)
Eminent Member
Topic starter answered:
RE: XL firmware 6.4.0 alpha

Perhaps the beta version will be better. Personaly i wait for the official version because i Had 3 head crashes and the belts  screamed.

Posted : 30/09/2025 7:14 pm
FoxRun3D
(@foxrun3d)
Illustrious Member
RE: XL firmware 6.4.0 alpha

Yeah, I had the belts actually ripped out of their holders...

It is telling (in several ways) that they moved from alpha to RC (no beta for reasons unknown to mankind) for other models but NOT the XL (and some others). I'm sure they're working on it but given how many reports there are on Github I wonder if they actually ever tested the alpha on an XL… Very disappointing.

Formerly known on this forum as @fuchsr -- https://foxrun3d.com/

Posted : 30/09/2025 7:20 pm
spearsdaz
(@spearsdaz)
Member
RE: XL firmware 6.4.0 alpha

Same here.  I am having the same problem too.  

Even when using a single tool head, mid print it will skip the belts.   Now the job is ruined by the rehome process.  The layers are off center.

Had to go back to previous firmware.

 

Posted : 30/09/2025 11:31 pm
spearsdaz
(@spearsdaz)
Member
RE: XL firmware 6.4.0 alpha

Same here.  I am having the same problem too.  

Even when using a single tool head, mid print it will skip the belts.   Now the job is ruined by the rehome process.  The layers are off center.

Had to go back to previous firmware.

 

Posted : 30/09/2025 11:31 pm
Junyoung
(@junyoung)
Active Member
RE: XL firmware 6.4.0 alpha

It seems that version 6.4 of the software has a toolhead collision issue. After updating to 6.4, I also experienced frequent collision alarms during the toolhead docking process after prints were completed. Upon checking, I found that the issue occurs when the printer homes and purges the tool at the beginning — it makes an unusual noise and the homing position becomes misaligned. All of these problems disappeared after I downgraded the firmware to version 6.26. Try downgrading the firmware and see if the issue is resolved

Posted : 01/10/2025 12:39 pm
1 people liked
Rufus
(@rufus)
Trusted Member
RE: XL firmware 6.4.0 alpha

I sure am thankful I am not the only one who is having this issue. Anyone having bed leveling issues now?? This thing is now trying to take 21 leveling measurements along with 5-10 small ones inside of those 21 and its taking 30mins. Then after it takes the measurements it fails. I have never had this issue unless a big glob of goo was stuck on the end of the nozzle. Anyone else??

Posted : 10/10/2025 10:20 pm
1 people liked
Rufus
(@rufus)
Trusted Member
RE: XL firmware 6.4.0 alpha

Just incase anyone else is having issues with this I just talked to Prusa and yes they are having issues with the same things. I went back to the 6.2 firmware and all the problems "so far" have gone away.

Posted : 10/10/2025 11:37 pm
2 people liked
Sejl
 Sejl
(@sejl)
Active Member
RE: XL firmware 6.4.0 alpha

 

Posted by: @rufus

I sure am thankful I am not the only one who is having this issue. Anyone having bed leveling issues now?? This thing is now trying to take 21 leveling measurements along with 5-10 small ones inside of those 21 and its taking 30mins. Then after it takes the measurements it fails. I have never had this issue unless a big glob of goo was stuck on the end of the nozzle. Anyone else??

 

Same + colission with dock after every print. No collision during dock calibration. So frustrating.

 

Posted : 28/10/2025 8:22 am
ElDudinero
(@eldudinero)
Active Member
RE: XL firmware 6.4.0 alpha

Same crash issues here.

Beware if you have enabled the Alpha-auto Update in the Prusa App.

The printer will download and propose updating to Alpha. 

Which of course will give us "Prusas collisive red light show".

I noted that after manually fixing the docking and continuing to print, there is a shift of exactly 5mm on the X-Axis.

When looking at the crash position, it seems it is 5mm offset in the other direction.

While calibrating (fiddling the sticks and screws) it does fine. 

Druring print pretest and filament change or manual pickup of the toolheads it does fine. 

Just while printing it crashes on pickup of the second tool.

While calibrating it does hit the sledge hard into the left railing - Different than version 2.4.0. 

So the error has to occur 

a) while calibrating just before each print or

b) somewhere in interpretation of the Gcode which is unlikely.

Solution: 

Fix it before all buy a Bamboo.

Workaround:

Downgrade to stable version and disable automatic proposal of alpha-Versions.

Posted : 28/10/2025 10:45 am
Mat
 Mat
(@mat-9)
Member
RE: XL firmware 6.4.0 alpha

Hey tank you so much, you save me !!

After one month struggling abd trying to solve my issues (filament stuck detection, disasters, etc...) I  just came back to the 6.2.5 and now it's really better 

I schould try the 6.2 as you did because I still have issues with retractations or that stupid detection or I dont know I m a simple user not a 3D printer ingenior.

I started 1 year ago with XL_firmware_6.1.3.bbf everything was perfect, and know I can tell all the upgrades after that were a mess.

I really regret that Prusa itself doesnt comunicate on that directly on the download page and still encourage to download the last very very bad firmware wich solves probalbly some issues but creates so many other ones at the same time. That doesnt express something serious.

Now I still need to disable stuck detection but I 'll go on the6.2.0 to get something working good.

 

Posted : 24/11/2025 1:59 pm
Gerald
(@gerald-6)
Active Member
RE:

Bonsoir

Et bien après les tests de la version 6.4.0 officielle, le problème de calibrage de pas à pas en phase est toujours inutilisable, VFA et vibrations machine plus importantes.

Que fait PRUSA pour cette XL

 

This post was modified 2 months ago by Gerald
Posted : 27/11/2025 6:17 pm
RGB
 RGB
(@rgb)
Eminent Member
RE: XL firmware 6.4.0 alpha

Je me pose la même question!!!

Je vais recharger la précédente version du firmare!

Prusa i3 MK3S Prusa XL 5 heads Dagoma Disco Ultimate bicolor Creality Ender 3

Posted : 09/12/2025 8:36 am
Philippe BAUER
(@philippe-bauer)
Eminent Member
Topic starter answered:
RE: XL firmware 6.4.0 alpha

IMPORTANT

It's not sufficient to come back to the previous firmware, i continued to have head crash !!!!

some parameters changed with the 6.4.0 remain always activ !!!

YOU MUST COMPLETLY RESET TO FACTORY SETTINGS! 

 

Merci en tous cas a Prusa de nous avoir livré un firmware "printer killer" j'avoue que en ajoutant cela au probleme de bruit de la core one, prusa commence a me cavaler sur les ...  Je précise que lorsque j'ai fait le reset usine ( on refait tout, c'est bien chia...nt)  j'ai retrouvé des mouvements de tete que je n'avais plus vu depuis un certain temps.  Bonne chance !

 

 

Posted : 09/12/2025 9:15 am
2 people liked
RGB
 RGB
(@rgb)
Eminent Member
RE: XL firmware 6.4.0 alpha

Personally, I stopped the machine as soon as I heard the first suspicious noises...And as mentioned above, I reinstalled the previous firmware; and I was lucky: no damaged belts and the machine returned to normal operation.

As @philippe-bauer wrote, "Thanks to Prusa for delivering a 'printer killer' firmware."

Prusa i3 MK3S Prusa XL 5 heads Dagoma Disco Ultimate bicolor Creality Ender 3

Posted : 16/12/2025 7:54 am
Diem
 Diem
(@diem)
Illustrious Member

As @philippe-bauer wrote, "Thanks to Prusa for delivering a 'printer killer' firmware."

This is not a firmware delivery.  You, and others in this thread, are commenting on an alpha release - by definition you must *expect* flaws, the whole point is to allow those in the community who wish to, to help test early builds, report on errors found and then to revert to a previous stable build until the next test cycle is released.

You have, of course, reported the errors you found on Prusa's github..?

Cheerio,

 

Posted : 17/12/2025 9:31 am
2 people liked
ElDudinero
(@eldudinero)
Active Member
RE: XL firmware 6.4.0 works fine!

FW 6.4.0 works perfectly and fine for several prints now. Absolutely flawless and great quality with very different and outright difficult filaments!

Thank you Prusa for fixing this so fast.

Personally I do not think (or want to argue) it was a "killer" Alpha. An Alphaversion is a prerelease with no guarantee which can (and mostly will) have bugs. To be cynic or sarcastic, hypocritical or outright vulgar - well it says more about the poster than about the product. In my case I was really pissed. Therefore the rant.

Conclusion: Do continue buying Prusa and sometimes a) if shit happens, take a deep breath (in the other direction) and b) be empathetic with the ranting runts. 😉

Chill and have a nice one!

 

Posted : 17/12/2025 1:39 pm
RGB
 RGB
(@rgb)
Eminent Member
RE: XL firmware 6.4.0 alpha

I won't get into a pointless argument.

I'll simply clarify that my previous post was misplaced, since the firmware I was referring to is XL 6.4.0, not XL 6.4.0 Alpha.

And I'll also clarify that it was indeed XL 6.4.0 that caused the malfunctions I mentioned on my machine.

Have a nice day !

Prusa i3 MK3S Prusa XL 5 heads Dagoma Disco Ultimate bicolor Creality Ender 3

Posted : 18/12/2025 8:02 am
Philippe BAUER
(@philippe-bauer)
Eminent Member
Topic starter answered:
RE: XL firmware 6.4.0 alpha

Ok i understand your position but i want to do an alert for Prusa, since many time i have too much more problems with my prusa printers and difficulties to do my job for my customers. XL head crash continuing before cleaning firmware, core one is not silent, settings doesn't work well even using accelerometer, and now i install the core one plus kit and have incredible mechanical problem. Obliged to use cutter and file to modify parts witch doesn't work. It 's not a great time for me and for Prusa.

!

Posted : 18/12/2025 5:24 pm
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