RE: Tension pulley broken
I'll be interested to hear your experience with that - seems like reasonable value.
I've used about a spool and a half of this filament. It's the first PC filament I have used so I don't have anything to compare it to, but it prints well and easily. I haven't done any mechanical testing with it, but at least visually it looks good, sticks well to the satin plate, and I haven't had any warping even on larger squarish prints.
I've only had a couple of issues that I think are unrelated to the filament itself but rather the print profile or my own error:
Toward the end of the first spool the residual bend in the filament when it came off the spool and some brittleness caused the filament to break in the extruder. I think I may have overheated the center of the spool when drying since my filament dryer heats from the center. I haven't been able to successfully load the remaining filament on that spool without it breaking so I moved to a new spool. I'm trying to be more gentle with the second spool so we will see how it goes.
The print profile I started with had zero print fan usage even on 100% overhangs. This caused problems when the first layer over infill as the filament sags down too much and can cause problems when the next layers go down. Using the print fan on the overhangs seems to have resolved this issue although the filament does sag down more than other filaments I print with.
I've printed four spare tension pulley holders, two stock and two of your design for the thermal inserts. They look good but I have not had a chance to install and test them yet.
RE: Tension pulley broken
Hey thanks for the info! I'll report back once I have the filament in hand and have printed one of the pulleys. I really hope I can get this thing printing this weekend. I feel dumb for having missed putting the pully screw back in all the way but I've been fiddling so much with it now it was bound to happen. I'm probably going to do a little more research before I pull the trigger on the hardened nozzles, but I'm leaning towards the high-flow since I've had the high flow nozzles on the MK4S'es for a while now and haven't had any clogging issues. Though I don't tend to print "filled" filaments very often.
I've used about a spool and a half of this filament. It's the first PC filament I have used so I don't have anything to compare it to, but it prints well and easily. I haven't done any mechanical testing with it, but at least visually it looks good, sticks well to the satin plate, and I haven't had any warping even on larger squarish prints.
I've only had a couple of issues that I think are unrelated to the filament itself but rather the print profile or my own error:
Toward the end of the first spool the residual bend in the filament when it came off the spool and some brittleness caused the filament to break in the extruder. I think I may have overheated the center of the spool when drying since my filament dryer heats from the center. I haven't been able to successfully load the remaining filament on that spool without it breaking so I moved to a new spool. I'm trying to be more gentle with the second spool so we will see how it goes.
The print profile I started with had zero print fan usage even on 100% overhangs. This caused problems when the first layer over infill as the filament sags down too much and can cause problems when the next layers go down. Using the print fan on the overhangs seems to have resolved this issue although the filament does sag down more than other filaments I print with.
I've printed four spare tension pulley holders, two stock and two of your design for the thermal inserts. They look good but I have not had a chance to install and test them yet.
RE: Tension pulley broken
Went ahead and ordered 7 of these
https://www.prusa3d.com/product/e3d-prusa-nozzle-high-flow-obxidian-0-4-mm
Not looking forward to having to run the nozzle recalibration on 5 extruders again lol
RE: Tension pulley broken
Went ahead and ordered 7 of these
https://www.prusa3d.com/product/e3d-prusa-nozzle-high-flow-obxidian-0-4-mmNot looking forward to having to run the nozzle recalibration on 5 extruders again lol
Crikey - she’s a ‘high maintenance’ mistress, that XL!
RE: Tension pulley broken
I don't print on it nearly as much as I should, but it has gotten better with firmware updates. It felt very untested after the 18 month preorder wait lol. I'm waiting for an XLS update of some sort at this point. I bought that puppy "fully assembled" as I was a little scare to build it from a kit. this core one upgrade makes me glad I did!
Crikey - she’s a ‘high maintenance’ mistress, that XL!
RE: Tension pulley broken
Thinking back to when I first broke a pulley, support suggested printing the part with any nylon filament.
There is some PA6-CF available on Amazon for £30 per Kg. No idea what the quality is like, and never heard of the brand either. The beauty of Amazon is returns are walk in the park if it's not fit for purpose.
Edit: I've found some for PA6-CF for £25 per Kg.
RE: Tension pulley broken
I'm still running my ABS pulley carriers. This morning there's a definite 2Hz drop in both belts. I'm not sure I was ever this rigorous in monitoring the PC-CF parts - I don't think this tension drop is unusual, but it's there.
I tweaked the tensions back to their correct values and then ran another VFA speed tower, and there is a very slight difference. But:
- No two VFA towers have ever looked exactly the same in my experience, and the difference in this case is at the same level of variability
- I forgot to rerun phase stepping and input shaping, and again the level of difference is similar to what I saw between before- and after- with the PC-CF mounts.
- Even with the tiny visible difference there's no clear-cut winner in my opinion.
I'm not going to post photos because the differences are too subtle to capture in a photo or two in my opinion.
So currently I'm not sure whether the plain ABS mounts are performing any differently from PC-CF - gut feeling is they aren't.
RE: Tension pulley broken
well if that's the case it seems abs is easier to get than pccf(at least from prusa). I'm currently getting a 3mf together for the XL to print that pully when the filament shows up. about to move the printer over by the window so I can put the ventialation host outside. Just waiting on amazon lol I'm going to be sad if I can't get this thing to pass calibration tests.
RE: Tension pulley broken
speaking of, it just got delivered...
RE: Tension pulley broken
so I got the pulley printed. I did at .99 extrusion multiplier at a 100% infill which seemed to be be pretty solid. The square nut was very difficult to get in. I had to use a very small flat bit screw driver to dig out a little bit to get the nut to fit in. It was snug fitting in the channel of the tensioner.
Did the following.
1. Put pulley back inline
2. Adjusted tensioners slightly to square gantry
3. Used tuner to get belts at right hz and ensured that gantry was still square
4. A ttempted to run the the y axis calibration. No joy
Prusa support did get back to me and asked me to send a vid showing that the gantry was square.
I'm about to send them these links
Gantry square verification
https://drive.google.com/file/d/1VWtKTX6aE9vLj_XDSoncNeX85Q7z_FVd/view?usp=drive_link
Failed Y axis calibration
https://drive.google.com/file/d/1uljRR24E6icja-qFh_SAZgNc3XAwISOW/view?usp=drive_link
Another day down a printer. We'll see what support comes back with
RE:
I don’t see how it can fail with a square gantry and the correct belt tension, so it will be interesting to hear what Prusa suggest.
Nevertheless, step 2 stands out. How much out of square was the gantry before you squared it up with belt tension. If I was in your shoes I’d want to get it completely square before putting ANY tension on the belts. I don’t really see why the result would be any different from what you have, but it’s worth eliminating that possibility.
Oh, and did you lube the tension screws?
And which belt tensioning method did you use - old or new?
RE: Tension pulley broken
Sometimes... I have had to resort to a full "factory reset". Yes, it is a pain in the a$$ because you lose your time zone, LCD footer settings, PrusaConnect settings, etc, etc. But in those cases where something weird is going on, this has been my go-to method-of-last-resort. Don't forget you will need a firmware file on your USB stick.
RE: Tension pulley broken
gantry was square or like maybe less than 1mm off before applying tension on belts. I used a little tension to eliminate that I used new method(front right). Yeah, I lubed the screws which does seem to help.
With regards to the full reset, I'm not against doing it but I'd like to work through with support and see what they say before I do it. like you said, it's kind of pain. I've messed with this enough today. I'll come back to it in the morning.
RE: Tension pulley broken
so I got the pulley printed. I did at .99 extrusion multiplier at a 100% infill which seemed to be be pretty solid. The square nut was very difficult to get in. I had to use a very small flat bit screw driver to dig out a little bit to get the nut to fit in. It was snug fitting in the channel of the tensioner.
Did the following.
1. Put pulley back inline
2. Adjusted tensioners slightly to square gantry
3. Used tuner to get belts at right hz and ensured that gantry was still square
4. A ttempted to run the the y axis calibration. No joyPrusa support did get back to me and asked me to send a vid showing that the gantry was square.
I'm about to send them these links
Gantry square verification
https://drive.google.com/file/d/1VWtKTX6aE9vLj_XDSoncNeX85Q7z_FVd/view?usp=drive_linkFailed Y axis calibration
https://drive.google.com/file/d/1uljRR24E6icja-qFh_SAZgNc3XAwISOW/view?usp=drive_linkAnother day down a printer. We'll see what support comes back with
Same happened to me. Was unable to pass Y calibration. After releasing the tension completely and allowing the belts to go slack, the gantry was no longer square. I had to manually bend it back then I tensioned the belts using the "old" method back to 85hz. After that, Y calibration passed. I'm not going to mess with this again and tempt fate.
RE:
I had exactly the same problem at the beginning, even though the portal was right angled, the 98/92 setting made the portal slightly crooked.... simply measure the distance from the screw... and seal it so that you have the same cm for both screws... otherwise you'll have 10cm on the left and only 5cm on the right.... get it straight and you won't have any problems.
To do this, open the roof or the side windows and measure...
RE: Tension pulley broken
I'm still running my ABS pulley carriers. This morning there's a definite 2Hz drop in both belts. I'm not sure I was ever this rigorous in monitoring the PC-CF parts - I don't think this tension drop is unusual, but it's there.
Just a thought Chris:
Is there a chance that now we're lubricating these tension screws there's a chance they're loosening by themselves as the printer operates?
Might be worth marking them in some way, just to rule this out.
Might also be why Prusa have never recommended doing so.
RE: Tension pulley broken
so... I think I have it fixed. This was user error. I went back and checked the y belt path and discovered that the back right pully attached to the motor was reversed. Totally my fault. it even says it in the directions. The calibration tests after tuning have now passed. I have a feeling the second upgrade, when I'm satisified with this first one, will go a LOT more smoothly...
RE: Tension pulley broken
just printed a benchy. everything seems to work. tensioning was done using new method. Going to do some more test prints today. Was a stupid rookie mistake and I'm kicking myself for it.
RE: Tension pulley broken
getting brave, trying some tpu. 92A. Sadly I'm pretty sure ninjaflex and softer is gonna be a problem. At least with the XL it's pretty easy to losen the fitting where the bowden tube comes in so you can help ninjaflex get loaded.
RE: Tension pulley broken
FWIW, I've done a little Overture 95A TPU w/ no difficulty.