Prusa CORE one filament extruder gear box making noise
I'm a prusa noob and have no idea what to do here. I've changed extrusion nozzles and replaced the entire hot tip assembly. It sounds like the gears are grinding in the extruder gear box.
Best Answer by David H. Brown:
It sounds to me that the filament is not making it through the lower hole in the main plate ( https://www.printables.com/model/1167816-core-one-printable-parts/files#preview.file.vpDJU ) of the Nextruder. As the gear pushes down on the filament, the filament doesn't find the hole and pushes back like a spring. You can open the idler and take a look.
The easiest fix is if this was just bad luck. Unload the filament, cut off and discard the section that the extruder will have chewed up. Consider cutting the tip of the filament twice at opposing angles to make a tapered point that might more easily find the hole. Make sure the leading section of the filament is straight, not kinked or bent, and try again.
Only slightly more difficult would be if you had a broken bit of filament stuck in there. Open the idler, check carefully; remove what doesn't belong.
Also, when it's cool, loosen the thumbscrews and be sure you have pushed the hot end fully up into the heat sink to minimize the chances that the filament gets caught on the top edge of the nozzle's tube. You'll note that there are two narrower sections on that tube into which the thumbscrews should fit. With the thumbscrews just the tiniest bit loose, they should still catch on the edges of those narrower sections if you try to let the nozzle slide lower. Here's a picture with an arrow pointing to the top of the nozzle reaching the lower hole in the main plate:
And here's what it looks like with filament loaded:
A more difficult fix would be needed if the main plate is somehow misaligned (or damaged). You might try redoing the Control/Calibrations and tests/Gear Calibration as it will loosen and retighten that area, potentially allowing a better alignment.
RE:
Are you me? I just finished setting my printer up last night and got 2 small prints done. On the third, nothing comes out. When I try to purge I get the same noises as you!
RE:
It sounds to me that the filament is not making it through the lower hole in the main plate ( https://www.printables.com/model/1167816-core-one-printable-parts/files#preview.file.vpDJU ) of the Nextruder. As the gear pushes down on the filament, the filament doesn't find the hole and pushes back like a spring. You can open the idler and take a look.
The easiest fix is if this was just bad luck. Unload the filament, cut off and discard the section that the extruder will have chewed up. Consider cutting the tip of the filament twice at opposing angles to make a tapered point that might more easily find the hole. Make sure the leading section of the filament is straight, not kinked or bent, and try again.
Only slightly more difficult would be if you had a broken bit of filament stuck in there. Open the idler, check carefully; remove what doesn't belong.
Also, when it's cool, loosen the thumbscrews and be sure you have pushed the hot end fully up into the heat sink to minimize the chances that the filament gets caught on the top edge of the nozzle's tube. You'll note that there are two narrower sections on that tube into which the thumbscrews should fit. With the thumbscrews just the tiniest bit loose, they should still catch on the edges of those narrower sections if you try to let the nozzle slide lower. Here's a picture with an arrow pointing to the top of the nozzle reaching the lower hole in the main plate:
And here's what it looks like with filament loaded:
A more difficult fix would be needed if the main plate is somehow misaligned (or damaged). You might try redoing the Control/Calibrations and tests/Gear Calibration as it will loosen and retighten that area, potentially allowing a better alignment.
RE: Prusa CORE one filament extruder gear box making noise
I've tried following your advice above, however my extruder keeps clicking and nothing is coming out. I even attempted to recalibrate the gearbox I suggested with no luck. My prusa one was a pre-assembled one. From what I can tell you'd need a special tool to open the gearbox and that only comes with the self-assembly kit. I'm a little nervous to touch that to see what else could be wrong.
To be a little more specific, when I open up the spring lock to investigate the extruder, I can see that the filament is not passing through into the nozzle. It is hitting the side of the hole and not going through no matter how much tapering I do
RE:
To be a little more specific, when I open up the spring lock to investigate the extruder, I can see that the filament is not passing through into the nozzle. It is hitting the side of the hole and not going through no matter how much tapering I do
How are the idler tension screws set? Perhaps they are too loose? Follow this as a guide: 18. Mounting the Idler-swivel assembly
RE: Prusa CORE one filament extruder gear box making noise
The screws are flush with the other side just as the instructions suggest. The filament, no matter how straight, hits just to the side of the extruder hole on the side closest to the front door to the printer.
RE: Prusa CORE one filament extruder gear box making noise
The screws are flush with the other side just as the instructions suggest. The filament, no matter how straight, hits just to the side of the extruder hole on the side closest to the front door to the printer.
Have you spoken with Prusa support then via online chat? That would be your next step.
RE: Prusa CORE one filament extruder gear box making noise
How would I go about doing that? There doesn't seem to be any option to cht anywhere that I can see.
RE: Prusa CORE one filament extruder gear box making noise
This has been a big issue when i swapped to the hardened nozzle, it just catches on the edge no matter how well its pushed up in the extruder, but with the original nozzle it just works. I sanded of the top edge ever so slightly to be sure there arent any sharp edges or burrs, that seems to have made it good enough to work. I think the issue is that the printed part is just not printed precisely, so it doesnt meet the nozzle perfectly.
RE: Prusa CORE one filament extruder gear box making noise
This has been a big issue when i swapped to the hardened nozzle, it just catches on the edge no matter how well it’s pushed up in the extruder, but with the original nozzle it just works. I sanded of the top edge ever so slightly to be sure there arent any sharp edges or burrs, that seems to have made it good enough to work. I think the issue is that the printed part is just not printed precisely, so it doesnt meet the nozzle perfectly.
The Prusa branded nozzles have a chamfer which presumably makes it easier for the filament to find its way into the heat break tube.
RE: Prusa CORE one filament extruder gear box making noise
I travel a bit for work so I've been gone for a few weeks. I think I found my problem. Thank you everyone for troubleshooting. Piece of broken filament was stuck in the idler. Thanks David Brown.
RE: Prusa CORE one filament extruder gear box making noise
Adding a bit of detail, the tension screws can be finicky. What works for one printer may not be 'perfect' for another. Also, everyone has a different notion of what 'flush with the back' means. I generally use my fingers to 'sense' when the screws are flush, then play with tension if I encounter oddness during printing (clicking at the extruder). Don't be too afraid to make adjustments, turning both screws in quarter turn steps either way to increase or decrease tension. For example, softer filament like TPU usually requires lower tension, harder filaments like PC a bit more tension.
If one setting worked for everything, Prusa would simply add a stop for the screws and we'd all be set. They left the range of tension adjustable for a reason.
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Adding a bit of detail, the tension screws can be finicky. What works for one printer may not be 'perfect' for another. ..
Interesting observation. There is some front-to-back play in the idler position and it would seem possible that, for example, tightening the rear screw more than the front might pull the idler toward the back and vice-versa. (Or would it push the idler toward the less tight side?) If so, this would potentially affect the guidance of the filament through the main plate. While I haven't had to fiddle with this myself on either my Mk 4S or CORE One, it might be useful for people who are having a lot of trouble with filament not loading through the Nextruder.
RE: Prusa CORE one filament extruder gear box making noise
Hi from a new Prusa CoreOne user having the same issue with horrible noises.
The filament just arrives till the beginning of the nozzle inside the extruder and stops there with the loud noise.
Happened on a new, assembled by myself kit after the second part I wanted to print.
Changed from the included Prusa test filament to some other filament and since then it can't load filament into the nozzle.
Cleaned the nozzle, let it heat at 250°C, tried the adjustment hints from here etc.
To be honest I'm disappointed as I bought the PRUSA because of their very good reputation of bring robust and reliable work horses.