Prusa Core One L - Persistent Ghosting and Mechanical "Clicking" from Left Motor Block
Hi everyone,
I’m reaching out to the community for help regarding my Prusa Core One L. I have been working with Prusa Support for about 2 months now, but despite numerous attempts and tests, we haven't been able to find a definitive solution to the following issues:
- Persistent Ghosting/Ringing: Highly visible on complex geometries and test models. It remains consistent regardless of software calibrations or mechanical adjustments.
- Asymmetric "Clicking/Rattling" Noise: Originating from the rear-left motor block. The noise occurs during Front-Rear, Left-Right, and diagonal movements (Front/Left - Rear/Right). It is reproducible even when moving the print head manually with motors off. I’ve also noticed that the clicking volume increases as belt tension increases.
Printer Specs:
- Model: Core One L
- Firmware: 6.5.3 (issue also present on 6.5.2)
- Filaments used: Buddy 3D PLA Black and other PLA filaments (prusa and no prusa).
Steps taken so far (under support guidance):
- Software Calibration: Multiple Input Shaper and Phase Stepping calibrations performed.
- Belt Tension: Checked and set within nominal range (92 Hz Upper / 88 Hz Lower).
- Axis Maintenance: Cleaned and lubricated Y-axis rods with Prusa lubricant.
- Pulley Troubleshooting: Swapped the motor pulleys between X and Y motors. This makes the clicking disappear temporarily (for about 48h of printing), but then it systematically returns. Grub screws are correctly tightened on the flat part of the motor shaft.
- X-axis Guide Rail: Loosened the screws, pressed the rail down, and retightened them from the outside toward the center as suggested by support.
- Slicer Profiles: Tested both "Speed" and "Structural" profiles and change speed and acceleration; ghosting remains evident, especially on faster profiles.
Video evidence and documentation:
I have compiled several videos and test files that clearly show the noise and the print defects:
- Complete Analysis (Photos, Videos and G-codes): Analysis Archive
- Click sound video (google photo link): Click video
- Ghosting Test with Buddy 3D PLA Black - HF nozzle 0.4 - 0.25 lyaer height - speed profile
Has anyone else encountered similar issues with a Core One L? The fact that the noise returns shortly after reseating the pulleys makes me wonder if there's a defect in the motor itself or an internal bearing in the left block.
Any advice or insight would be greatly appreciated. Thanks!
RE: Prusa Core One L - Persistent Ghosting and Mechanical "Clicking" from Left Motor Block
Could you also upload the .3mf file which produces the ghosting print to your Google drive please?
RE: Prusa Core One L - Persistent Ghosting and Mechanical "Clicking" from Left Motor Block
Sure,
I add the .3mf project. Ghosting Test project
Thanks
RE: Prusa Core One L - Persistent Ghosting and Mechanical "Clicking" from Left Motor Block
Thanks!
It is a bit hard to see from the photo how pronounced the overshoots (ringing) actually are. A lot of the contrast is from the filament becoming glossy (deeper black) when printed slowly, while it remains matte black during the faster stretches, I think. Where does the light actually come from in that photo? Do the bright lines represent areas where the filament bulges outward?
If you suspect that the clicking (which you seem to have isolated to one motor) is related to the ringing: You could try turning the test object to +- 45° angles, such that the quick steps during the print align with movements of only one motor or the other. Does that give a pronounced change in the ringing? If so, the two observations may indeed be related.
There have been a few reports in the Core One forum section about idlers making clicking noises. Some users have replaced the idlers; some have reported that they replaced the shafts on which the idlers sat. (The Core One simply uses screws for those, not proper shafts with a smooth section that exactly fits the ball bearing in the idler. I assume it's the same in the L?) See this thread: https://forum.prusa3d.com/forum/prusa-core-one-hardware-firmware-and-software-help/new-c1kit-strange-clicking-rattle-noise-from-y-axis-stepper-area/
But I am not sure what to recommend to you regarding the idlers. Replacing them all just to eliminate this possibility is time-consuming, and your printer is probably still under warranty? Maybe best to get back to Prusa support, if you have not discussed this specific potential cause with them yet.