Hey all, I am in the middle of building a new printer but am at a standstill because my cheap prusa i3 is jamming up and in general tossing small slivers of my soul into the abyss in the form of misshapen blobs of plastic jk (not really it would be nice if it did that much). To start I will post videos and pics of any angle requested I just have to wait until tomorrow night to do so as I am working late tonight to finish up a project. The story up to this point: Because I am cheap and at the time was on a very tight budget I ordered the absolute cheapest kit I could find that had a heated bed. Printer: Folger Tech RepRap Prusa i3 Clear Frame Full 3D Printer Kit http://www.ebay.com/itm/Folger-Tech...e-Full-3D-Printer-Kit-RAMPS-GT2-/231301357105 Filament: Black PLA http://www.amazon.com/gp/product/B00JQK4RSG I used this for the first 2 months no issues. Blue PLA http://www.amazon.com/gp/product/B00JQK4UD8 Yellow PLA http://www.amazon.com/gp/product/B00JQK4YMK It went together with just a few issues. The main one being the acrylic frame cracking and some spider web fractures from over tightening bolts. Nothing that a little acrylic glue could not fix. My first two months of use where uneventful I was printing fine with the Black PLA and I started to feel like I knew what I was doing... well then I started getting small jams and a print fails but it was not anything that felt abnormal compared to what I read on the forums. I wanted to do some prints in different colors so i ordered the blue and yellow and after trying out both and getting nothing but failed prints I switched back to the black and still all my prints where failing. What I have done to fix/trouble shoot the issue. I have replaced: nozzle nozzle throat throat tubing switched from direct drive to a bowden (see below for details) I have adjusted: I have changed the print temperature from 185 up to 230. This first two months I ran fine at 185. Switching from direct drive to bowden: I took apart the direct drive extruder that looks like this Extruder Print Head and found that the v groove bearing was in peaces so I placed an order for a replacement from china because I could not find any state side that where not crazy priced. It was going to take a month to get the part in so I ordered a Airtripper Bowden Extruder and converted my direct drive to a franken bowden (I will post a picture later that will explain this) What I need: I probably have more details that will help solve this problem but am so frustrated that my brain is not thinking to include them. I need you to help me ask the right question and post the info needed to help solve this. If you ask me to post a picture and/or video of it doing something I will try to get it posted. I am willing to do what it takes to get this thing working.
I personnally have a i3 for 1.5 years now and I'm building another one now, the same as Robert Hummel (we were working together on the project). So first send me a picture of one of your good print and one of the bad one, I want to see the first layer (so a picture from the bottom) and one from the side. Maybe a picture of your extruded filament when you ask your program to extrude manually could be helpful. What software/firmware combination do you use? Personally, I use OpenScad, Slic3r and Pronterface. If you use slic3r too send me your settings I'll look at them. Can you send me a simple Gcode example too? Well start with that
I will get the pictures/videos posted this ether tomorrow night or Saturday. I am stuck at work and have to get a milestone finished by tomorrow. I will post the settings as soon as I can get my remote connection working. I might have to go home to restart my computer later. Software: Rhino3d Slic3r Pronterface
As you use the same software chain as I do it should be easy to see if there is a problem there. Waiting tomorrow to continue the troubleshooting I understand your frustrations, I got all the possible problems with my i3 Nothing's impossible to fix
How do you store your filaments? Do you measure diameter and input into slicer? when you say throat tube, I am assuming you mean your ptfe liner, does it stop at the nozzle, or extend into. when you replaced it, how did you measure it for length? The extruder you linked has a "delrin plunger", i think its called. And they are know to be sub-par. What the open source communtiy replaced that with, is that began the slippey slope for MBI. You should be able to utilize any of the Rep1/2/dual spring loaded bearing extruders available on thingiverse. I essentially purchased the same extruder for my core xy, but will be using 3in1 aluminum extruders Is your thermal barrier a straight through bore, or is it stepped. Check out the Carl Raffle thermal barriers. I will try and dig up the science behind " the magic " as it is referred to. Qu-BD is decent in the states for cheap parts, hot end .
My workshop - or as my wife calls it the guest room is on the second floor in a room with the vents closed and door kept shut. Filament storage- In a filament spool shaped hole in the wall. jk - I have a box on the floor that I keep all my filament in. I keep the filament sealed in the bag it came in until I start to use it them it sits on my printer table. measure diameter- I have not done this I guess I ignorantly thought i ordered 1.75 and that is what it was. throat tube - Maybe Threaded Thermal Barrier. the threaded tube between the hotend and the aluminum block that my bowden connector is on. ptfe liner - Yes, the tube is ptfe lined. I have a few backups and have replace the tube on one of them. does it stop at the nozzle - I am assuming you are asking if the ptfe tube extending into the nozzle? if that is what you are asking then no it does not. It is a threaded nozzle. how did you measure it for length - what replacement part are you referring too? extruder I linked - I have replaced this with a bowden extruder. Is your thermal barrier a straight through bore - I am assuming yes. Qu-BD - the item you linked look identical to what I have. I will post pictures this weekend.
So, I wasnt sure if you wanted to stay bowden or not, and I only linked the qu-bd as a stateside, alternative to buying a whole new assembly. I asked about the filament diameter, even though you buy 1.75 its not 1.75 and it varies. If the filament is 1.81 and the slicer thinks its 1.75, where does that extra volume of pastic go? it builds pressure until it clogs. I am new to this and have 0 experience with bowden, and ramps. There are some nozzles with a 3mm opening, designed to have the ptfe go all the way into the cone. I was asking how you measured the length of the PTFE? Is the tube being pinched and restricting flow? is it too short and creating a plug when retracting? Humidity affect some filaments greatly. it makes them swell and causes jams.
If you were getting good quality prints beforehand then it likely isn't an issue with your software unless you made a change. Slic3r settings are different though, but again, things were working beforehand. In your opinion, is the issue with the hotend/filament drive or with print adhesion to the build plate? Sounds like the former. I've struggled with a nozzle that had a failed liner before and though I replaced the liner it never seemed to perform reliably again. I've also had issues with a E3D v5 clone that was useless with PLA but could handle ABS decently. PLA is the easiest to get good prints with, but the hardest to build a reliable hot end for due to its stickiness. I would first make sure the filament drive is working well and not missing steps or stripping filament. Then check to see if the hotend can be hand fed filament and see how much pressure is required. Try it at both 200 and 220C to feel if there is a difference. It shouldn't require much force otherwise there is either a blockage, liner failure, or too much flow resistance with PLA. If this works manually then see if you can get it to extrude properly with pronterface. If this works as well then the issue may be related to you retraction settings and the nozzle design (heat break/cooling/backpressure/etc). If your issue is a lack of print adhesion to the build plate then there are several easy and cheap solutions. Especially since you already have a heated bed.
I think I like the bowden setup. I will have to check the diameter and see if that is part of the issue. I did have an issue once with the ptfe tube not being long enough but that is the one I replaced because it was creating a plug. My opinion on what the cause of the issue has swayed allot. I am getting very good bond to the build plate (glass with hair spray) so if it an issue with the first layer it might be getting smashed but it usually does not jam till about the 3 layer. It could be I do not have the build surface leveled well. so if I tell it to extrude 10mm it does fine. if I tell it to extrude 100mm it will sometimes jam up around 40mm in and sometimes it does 100mm fine. This is the same with both direct drive and bowden. I have also replaced all the parts on the hotend. and when I switched to bowden it was a complete unit that I replaced. The new bowden is the same design hotend.
The first motor on it burned out so I replaced temporarily changed it with one from openbuild but it belonged to a differnt project so I ordered a different motor for it. I did the 100mm calibration and changed my esteps.
I just got home I am going to do take some photos and screen shots of settings and make a large post.
First post. let me know if images done show up. This is pictures of the bottom layer. Started to print a 20mm cube jammed on layer 3 Last successful print First print that was not a calibration. -Spool holder
I'll need your slic3r settings, for your first layer, either it is too high, or you're underextruding. You can export them with slic3r, I'll load them here, it will be faster than taking pictures of your screen. What firmware do you use? Take pictures of your i3 too.
# generated by Slic3r 1.1.7 on Fri Feb 6 22:36:57 2015 [filament:Simple Mode] bed_temperature = 62 bridge_fan_speed = 100 cooling = 1 disable_fan_first_layers = 1 extrusion_multiplier = 1 fan_always_on = 1 fan_below_layer_time = 60 filament_diameter = 1.75 first_layer_bed_temperature = 67 first_layer_temperature = 0 max_fan_speed = 100 min_fan_speed = 35 min_print_speed = 10 slowdown_below_layer_time = 30 temperature = 185 [filament:Simple Mode Black PLA] bed_temperature = 62 bridge_fan_speed = 100 cooling = 1 disable_fan_first_layers = 1 extrusion_multiplier = 1 fan_always_on = 1 fan_below_layer_time = 60 filament_diameter = 1.75 first_layer_bed_temperature = 67 first_layer_temperature = 210 max_fan_speed = 100 min_fan_speed = 35 min_print_speed = 10 slowdown_below_layer_time = 30 temperature = 210 [filament:Simple Mode Blue PLA] bed_temperature = 67 bridge_fan_speed = 100 cooling = 1 disable_fan_first_layers = 1 extrusion_multiplier = 1 fan_always_on = 1 fan_below_layer_time = 60 filament_diameter = 1.75 first_layer_bed_temperature = 75 first_layer_temperature = 230 max_fan_speed = 100 min_fan_speed = 35 min_print_speed = 10 slowdown_below_layer_time = 30 temperature = 230 [filament:Yellow PLA] bed_temperature = 62 bridge_fan_speed = 100 cooling = 1 disable_fan_first_layers = 1 extrusion_multiplier = 1.1 fan_always_on = 1 fan_below_layer_time = 60 filament_diameter = 1.75 first_layer_bed_temperature = 67 first_layer_temperature = 0 max_fan_speed = 100 min_fan_speed = 35 min_print_speed = 10 slowdown_below_layer_time = 30 temperature = 185 [presets] filament = Simple Mode Black PLA.ini print = .3L 6 W 50%F NS.ini printer = Simple Mode.ini [print:.3L 6 W 50%F NS] avoid_crossing_perimeters = 0 bottom_solid_layers = 3 bridge_acceleration = 0 bridge_flow_ratio = 1 bridge_speed = 60 brim_width = 0 complete_objects = 0 default_acceleration = 0 dont_support_bridges = 1 external_perimeter_speed = 70% external_perimeters_first = 0 extra_perimeters = 1 extruder_clearance_height = 20 extruder_clearance_radius = 20 extrusion_width = 0 fill_angle = 45 fill_density = 30% fill_pattern = rectilinear first_layer_acceleration = 0 first_layer_extrusion_width = 200% first_layer_height = 0.35 first_layer_speed = 30% gap_fill_speed = 20 gcode_comments = 0 infill_acceleration = 0 infill_every_layers = 1 infill_extruder = 1 infill_extrusion_width = 0 infill_first = 0 infill_only_where_needed = 0 infill_speed = 60 interface_shells = 0 layer_height = 0.3 min_skirt_length = 0 notes = only_retract_when_crossing_perimeters = 0 ooze_prevention = 0 output_filename_format = [input_filename_base].gcode overhangs = 1 perimeter_acceleration = 0 perimeter_extruder = 1 perimeter_extrusion_width = 0 perimeter_speed = 30 perimeters = 3 post_process = raft_layers = 0 resolution = 0 seam_position = aligned skirt_distance = 4 skirt_height = 1 skirts = 3 small_perimeter_speed = 30 solid_fill_pattern = rectilinear solid_infill_below_area = 70 solid_infill_every_layers = 0 solid_infill_extrusion_width = 0 solid_infill_speed = 60 spiral_vase = 0 standby_temperature_delta = -5 support_material = 0 support_material_angle = 0 support_material_enforce_layers = 0 support_material_extruder = 1 support_material_extrusion_width = 0 support_material_interface_extruder = 1 support_material_interface_layers = 3 support_material_interface_spacing = 0 support_material_interface_speed = 100% support_material_pattern = pillars support_material_spacing = 2.5 support_material_speed = 60 support_material_threshold = 0 thin_walls = 1 threads = 2 top_infill_extrusion_width = 0 top_solid_infill_speed = 50 top_solid_layers = 3 travel_speed = 130 [print:Simple Mode] avoid_crossing_perimeters = 0 bottom_solid_layers = 3 bridge_acceleration = 0 bridge_flow_ratio = 1 bridge_speed = 60 brim_width = 0 complete_objects = 0 default_acceleration = 0 dont_support_bridges = 1 external_perimeter_speed = 70% external_perimeters_first = 0 extra_perimeters = 1 extruder_clearance_height = 20 extruder_clearance_radius = 20 extrusion_width = 0 fill_angle = 45 fill_density = 50% fill_pattern = rectilinear first_layer_acceleration = 0 first_layer_extrusion_width = 200% first_layer_height = 0.35 first_layer_speed = 30% gap_fill_speed = 20 gcode_comments = 0 infill_acceleration = 0 infill_every_layers = 1 infill_extruder = 1 infill_extrusion_width = 0 infill_first = 0 infill_only_where_needed = 1 infill_speed = 60 interface_shells = 0 layer_height = 0.1 min_skirt_length = 0 notes = only_retract_when_crossing_perimeters = 1 ooze_prevention = 0 output_filename_format = [input_filename_base].gcode overhangs = 1 perimeter_acceleration = 0 perimeter_extruder = 1 perimeter_extrusion_width = 0 perimeter_speed = 30 perimeters = 6 post_process = raft_layers = 0 resolution = 0 seam_position = aligned skirt_distance = 4 skirt_height = 1 skirts = 2 small_perimeter_speed = 30 solid_fill_pattern = rectilinear solid_infill_below_area = 70 solid_infill_every_layers = 0 solid_infill_extrusion_width = 0 solid_infill_speed = 60 spiral_vase = 0 standby_temperature_delta = -5 support_material = 1 support_material_angle = 0 support_material_enforce_layers = 0 support_material_extruder = 1 support_material_extrusion_width = 0 support_material_interface_extruder = 1 support_material_interface_layers = 3 support_material_interface_spacing = 0 support_material_interface_speed = 100% support_material_pattern = pillars support_material_spacing = 2.5 support_material_speed = 60 support_material_threshold = 0 thin_walls = 1 threads = 2 top_infill_extrusion_width = 0 top_solid_infill_speed = 50 top_solid_layers = 3 travel_speed = 130 [printer:Simple Mode] bed_size = 200,200 end_gcode = G28 X0 Y0 ; home X axis and y axis\nM104 S0 ; kill extruder temperature\nM140 S0 ; kill bed temperature\nM84 ; disable motors\nM107 ;turn fan off\n extruder_offset = 0x0 gcode_flavor = reprap layer_gcode = nozzle_diameter = 0.4 print_center = 100,100 retract_before_travel = 2 retract_layer_change = 1 retract_length = 6 retract_length_toolchange = 10 retract_lift = 0.3 retract_restart_extra = 0 retract_restart_extra_toolchange = 0 retract_speed = 30 start_gcode = M106 S255 ;turn on fan full power\nG21; set mm units\nG28 ;home all axis\nM190 S[first_layer_bed_temperature] ; set and wait for bed temp to be reached\nM104 S[temperature] ; set extruder temp and start heating\nG90; set absolute coordinates\nG1 Z5 F300 ;move platform down 5mm\nG1 X10 Y10 F3000 ;move to front left corner\nM109 S[temperature]; wait for extruder temp to be reached\nG1 Z[first_layer_height] F200 ;move platform close to nozzle\nG92 E0; reset extrusion distance\nG1 E7 ;extrude anchor\n\n toolchange_gcode = use_firmware_retraction = 0 use_relative_e_distances = 0 vibration_limit = 0 wipe = 0 z_offset = 0 [settings] autocenter = 1 mode = expert [simple] avoid_crossing_perimeters = 1 bed_size = 200,200 bed_temperature = 62 bottom_solid_layers = 3 bridge_acceleration = 0 bridge_fan_speed = 100 bridge_flow_ratio = 1 bridge_speed = 60 brim_width = 0 complete_objects = 0 cooling = 1 default_acceleration = 0 disable_fan_first_layers = 1 dont_support_bridges = 1 duplicate_distance = 6 end_gcode = M104 S0 ; turn off temperature\nG28 X0 ; home X axis\nM84 ; disable motors\nM107 ;turn fan off\n external_perimeter_speed = 70% external_perimeters_first = 0 extra_perimeters = 1 extruder_clearance_height = 20 extruder_clearance_radius = 20 extruder_offset = 0x0 extrusion_axis = E extrusion_multiplier = 1 extrusion_width = 0 fan_always_on = 0 fan_below_layer_time = 60 filament_diameter = 1.75 fill_angle = 45 fill_density = 0% fill_pattern = rectilinear first_layer_acceleration = 0 first_layer_bed_temperature = 67 first_layer_extrusion_width = 200% first_layer_height = 0.4 first_layer_speed = 30% first_layer_temperature = 205 g0 = 0 gap_fill_speed = 20 gcode_arcs = 0 gcode_comments = 0 gcode_flavor = reprap infill_acceleration = 0 infill_every_layers = 10 infill_extruder = 1 infill_extrusion_width = 0 infill_first = 0 infill_only_where_needed = 0 infill_speed = 60 interface_shells = 0 layer_gcode = layer_height = 0.3 max_fan_speed = 100 min_fan_speed = 35 min_print_speed = 10 min_skirt_length = 0 notes = nozzle_diameter = 0.4 only_retract_when_crossing_perimeters = 1 ooze_prevention = 0 output_filename_format = [input_filename_base].gcode overhangs = 1 perimeter_acceleration = 0 perimeter_extruder = 1 perimeter_extrusion_width = 0 perimeter_speed = 30 perimeters = 3 post_process = print_center = 100,100 raft_layers = 0 resolution = 0 retract_before_travel = 2 retract_layer_change = 1 retract_length = 1 retract_length_toolchange = 10 retract_lift = 0 retract_restart_extra = 0 retract_restart_extra_toolchange = 0 retract_speed = 30 seam_position = aligned skirt_distance = 6 skirt_height = 1 skirts = 1 slowdown_below_layer_time = 30 small_perimeter_speed = 30 solid_fill_pattern = rectilinear solid_infill_below_area = 70 solid_infill_every_layers = 0 solid_infill_extrusion_width = 0 solid_infill_speed = 60 spiral_vase = 0 standby_temperature_delta = -5 start_gcode = M106 S255 ;turn on fan full power\nG28 ; home all axes\nG1 Z5 F5000 ; lift nozzle\n support_material = 1 support_material_angle = 0 support_material_enforce_layers = 0 support_material_extruder = 1 support_material_extrusion_width = 0 support_material_interface_extruder = 1 support_material_interface_layers = 3 support_material_interface_spacing = 0 support_material_interface_speed = 100% support_material_pattern = pillars support_material_spacing = 2.5 support_material_speed = 60 support_material_threshold = 0 temperature = 200 thin_walls = 1 threads = 2 toolchange_gcode = top_infill_extrusion_width = 0 top_solid_infill_speed = 50 top_solid_layers = 3 travel_speed = 130 use_firmware_retraction = 0 use_relative_e_distances = 0 vibration_limit = 0 wipe = 0 z_offset = 0
may be faster like that... load those settings (they are the one I use) and try a calibration cube just to see what happens. Save your settings first to be able to bring them back afterwards!!! By the way, I'm pretty sure I'll be online all night long if you want to do other tests.
Ahhh, I had a rough night. I would have some more pictures but my phone died. I will get some up soon. so What I did after loading your file. I suspected there might be a gap between the nozzle and the heat break so I rebuild it making sure there was zero gap. Not really related to the issue but still a change. I installed an aluminum build plate. What all did this involve me doing, I had to flip my heated bed soldered and re-solder the connections and install the new plate. I am not sure how to protect the surface so I put my glass build plate back on it for now but I did notice a more consistent temperature on build surface. So what have I found out. First I am not very fond of your @dddman pre-build movements. It makes a smear on the surface or if I am not 100% level it drags on the surface. When I first install the filament I can push filament though as long as I don't stop. Once I stop and let it sit it might push filament or it might not. I think the jam is happening becasue the filament is melting too high. Below is a picture of what the filament looks like after a jam. There is a noticeable diameter change. The diameter coming in is 1.7mm and the tip above is 2.1mm at its widest point.
I think I am going to run a few test with abs and see how that works out. I know that pla is not as slick as abs but I really hate the smell of abs.
normally your head is way above the bed while homing your X and Y axis so the head shouldn't drag on the bed... anyway, did you try a test print with these settings? Send me a picture of a test cube I'll be able to compare it the settings changed something. It's normal that the tip of the filament is bigger when you remove it from the extruder as it melt in a little reservoir before being extruded.
New update, I think I am ether going to have to scrap all my pla or the hotend I have just decided pla does not agree with it. @dddman I would have posted pics of it printing but it would not print past the first layer before jamming. I was able to print abs just fine...once I figured out the temps needed to get it to stick to my build surface. first abs print. I did not have my home layer tuned in well so it almost did not stick. I will post the picture of the second print and videos once they upload to Google.
I printed it at 230 and a bed temp of 95. I dont have a on my prints. That was an aaddition I was trying to add when all this started.
I know you're now using Bowden... Are you still using that aluminum chassis bar, similar to the one from qubd? Over in the clone world that chassis is know to be the wrong dimensions. It is not quite thick enough to cool properly, a quick fix was to use a thin bass m6 nut under it, above the heat break.
So thinking it might be a heat issue I ordered this last week. it should be in late next week. http://www.ebay.com/itm/321463523942
Could you post some pics of your hot / cold ends. Do you have a fan cooling your cold side? Does the Bowden setup have a similar heat break then the direct drive? I am going to have to learn this, just got a smoothie board going to build a delta I think
Yeah I will get them posted as soon as I have a working camera. I tripped last night walking to my car and broke my phone.
