Hi all, this is my first post and it's a long one. I'm relatively new to working with UM machines and I've got two of them at work that I'm having some extrusion issues with. Both machines are UM2e's with Olson Blocks installed and 0.4mm E3D nozzles.
Basically, I'm seeing a lot of gaps between lines in the infill and between perimeters which is an obvious sign of under extrusion. If I try and print at what I would consider normal temperatures for PLA (190-210C) the extruder will click and you can tell that it's obviously missing steps. With PLA, I have to crank the temperature up to 225-235C to stop the extruder from skipping at which point print quality goes down hill. Similarly, with PETG I have to print between 245-255C, which is also quite hot compared to normal.
I've rebuilt the hotend on both machines with new nozzles, PTFE couplers and bowden tubes and I've not seen any improvement in extrusion quality. The only thing that seems to work are unreasonably high temperatures or really low speeds. Looking at the volumetric flow numbers, I'm well within range of what I've read the machine should be able to do, so I'm a bit stumped as to why I can't achieve good flow. Nozzle temperature varies by a few degrees during printing (+/- 2C from target), but what I'm seeing in the microscopy pics below is that heat transfer just isn't sufficient to provide consistent extrusion.
See below for some PETG test prints that I did for an example of the issue.
Left, Cura defaults for 0.2mm layer height.
Middle, Cura defualts, but slowed inner perimeters to 30 mm/s to match outer perimeter
Right, Cura defaults, but all speeds set to 20 mm/s
Left side print from top photo - Matterhackers black PETG - Cura defaults for 0.2mm layer height, 0.4mm line width, 30mm/s outer walls and top infill, 60 mm/s for inner walls. Note the gaps between perimeters and top infill lines. Top infill and outside perimeters printed at 30 mm/s have a volumetric flow of 2.4 mm^3/s, inner perimeters are double that at 4.8mm/s. Both should be within range of what a UM2 can do from what I've read (10 mm^3/s max, <5 mm^3/s preferred).
Middle print from top photo - Matterhackers black PETG - Cura defaults for 0.2mm layer height, 0.4mm line width. Inner walls slowed to 30 mm/s. Volumetric flow rate of 2.4 mm^3/s
Right side print from top photo - Matterhackers black PETG - Cura defaults for 0.2mm layer height, 0.4mm line width. All speeds set to 20 mm/s. Volumetric flow rate of 1.6 mm^3/s
I think both machines are running the stock 25W heater cartridge. I have the 35W versions on hand and can install, but since I'm not seeing a temperature drop while printing faster (30-60 mms/) I don't think that's going to change anything since the lower wattage units seem to be able to keep up with power demand. The only other thing I can think of to fix the issue is upgrading the extruder to supply more feed pressure to get a more consistent extrusion, but I don't really want to drop $400 on the UM2+ upgrade kit to find out that that doesn't work either.
Any ideas to fix this, or do I just have to print at super slow speeds with these machines?