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I am having a strange intermittent printing error specific to one particular object I'm trying to print.

A picture of my print error

My printer is a BCN3D Sigma R17. I am printing a thin wall (0.6mm) cup object. I'm using:

  • Simplify3D with Sigma Progen profiles
  • 0.6mm brass nozzle (w/thermal paste)
  • 0.1mm layer height
  • Spiral (vase mode)
  • Filaform PLA.

As you can see in the images, the first few layers print ok, but then the nozzle seems to collide/penetrate the previous layer and grinds against it as it moves around in a circle. The result is a combination of rough textured surface and good quality surface. One half of the print also seems to be thicker, presumably from the increased extrusion width caused by squashing layers in the z-axis. I’ve tried

  • changing model's wall thickness,
  • disabling spiral mode
  • increasing layer height
  • changing filament
  • upgrading printer (latest stepper drivers)
  • changing extrusion width
  • performing full calibration

All without success. You can view the gcode and S3D fff profile here: https://drive.google.com/drive/folders/0B6SnaYyiYI7vcGU1U3Uxb0RrX3M?usp=sharing

The image shows some filament left hanging from a stopped print. It seemed to be squeezed out from excess pressure, as if it was being blocked during the print due to being pushed against the layers.

1 Answer 1

Although this reply is pretty late, there are some issues I would like to point out:

  1. In the cup.gcode file there seems to be an issue with the layer height. The height for the second layer is larger than the third layer!
  2. If you see that the cup prints good on one side (also thicker on one side), this is a good indication of a bed leveling issue. Although you indicate you did a full calibration, I would still re-check the bed leveling. The extruder head movement in the X-Y should be as closely parallel to the bed as possible.
  3. The cooling settings in your Simplify3D profile are low. I would bump up the fan speed to ensure that the strand being laid down is sufficiently cooled to prevent overheating from subsequent loops.
  4. Try slowing down the Z-axis speed. Stepping too quickly can cause skipped steps depending on the acceleration settings and mass/inertia of the head.