cheuschober

Thanks @PaulKuiper -- that definitely had me along the right track and was consistent with what I was thinking. After about 50-ish calibration prints I think what was happening was a confluence of multiple factors. The biggest benefit came from upping the build volume temp from the default of 35C to 50C and changing fan speed from 15% to 65%. That had the most dramatic effect on what I suspect was warping due to the top/bottom having so much more plastic than the body and the forces related to that pulling inward. Moving more air onto the freshly melted plastic and keeping a generally warmer chamber had a dramatic, but not complete, effect. I then *also* had to dial down the skin flow by a couple % as you suggested to get a clean corner.

Here's a calibration cube that's showing the same effect. Anywhere there's a bottom or a top, there's bulging that seems to get worse the closer it gets to the top / bottom. This cube measured at Layer 4 or 195 was effectively +0.1mm over layers in the center. While initial layer horizontal expansion can help with elephants foot, it seems like something else is either bulging with top/bottom or the walls are collapsing. TopSurfaceLip.3mf

Oh, also, here's a small test model though it obviously shows up on multiple models: ChamferBulge.obj

Hi! Yes. I'm running Cura 5.1 with the latest 8.x firmware. I didn't have this ringing until I changed the belts so I wonder if this is an artifact of what's now a rather rigid system (by comparison). It's pretty consistent on both X&Y. Here's the profile I've been using thus far which was largely based on the default Engineering Fine profile ultimaker-s5-abs-calibration.curaprofile

Absolutely! Here are two calibration print examples. There's something happening at the top and I'm realizing it really doesn't matter if it's chamfered or not -- something is expanding beyond or pushing the walls out and I cannot seem to narrow the relevant setting in Cura... I also know I've got a bit of elephants foot there which I'll eventually dial in via Initial Layer Horizontal Expansion.

Hi @MariMakes If the bulging wasn't happening right at the point where the angle of the chamfer hits, I'd be more inclined to investigate that. I The other banding is just some ringing from a rather fast jerk (30mm/s). If it wasn't clear, this isn't the print orientation -- it's flipped on its side 90 deg so I could show the funny bulging along the XY where the chamfers angles meet the walls.

Hi. I just did a major servicing on my S5 (all belts changed, axles realigned, new feeders (fine knurl), etc) and I've been run calibration prints when a new problem evolved and I'm not sure what to call it which makes looking for a solution much harder. The print here is a califlower. I can't include the STL for reasons that it's not my model to share but this is an XY+Skew calibration tool being printed here at 0.1mm with Ultimaker ABS and the AA0.4 print core. This model has both a top and a bottom chamfer and at both there appears to be some kind of bulging or the walls are collapsing inward a bit. As I said, I'm not sure if this has an official name and/or solution but I'd really appreciate it if someone could point me in the right direction. ultimaker-s5-abs-calibration.curaprofile

Hi @dsp... These were printed simultaneously but I've done many individual prints. At 2% fan speed it's even worse than the worst of this bunch. I have tried it with multiple ultimaker ABS filaments and multiple ABS's in general. I have often wondered if I have a broken thermal measure but I think(?) those are in the print cores and I have these problems across print cores too. <sigh) About every 6 months or so, I seem to get serious about trying to dial in this printer and then I get discouraged and the cycle repeats 6 months later. </sigh>

Hi. I've been trying to calibrate my Cura settings / S5 with Air Manager and I'm having a difficult time interpreting the results of this most recent test. I'm hoping someone else might have an idea of what I'm looking at here. These are 3 temperature towers per the Calibration Shapes extension. The material is Ultimaker ABS black that's been recently dried. I've been having a difficult time interpreting the results of single towers so I opted to explore if there's something up with resonances or the bed. The results are definitely.... interesting, though I'm not sure I know how to interpret them. Calibration print profile starts with the Ultimaker ABS / Normal profile and makes the following changes: - Nozzle Size : 0.4 - Layer Height : 0.16 - Initial Layer Height : 0.2 - Line Width : 0.4 - Wall Line Count : 3 - Top/Bottom Thickness : 0.8 mm - Enable Bridge Settings : True - Use adaptive layers : False Additionally, my first one of these was such a disaster, I added: - Print Speed : 40.0 mm/s - Fan Speed : 50.0 % As you can see the results in each of the corners is rather different. I've done a manual bed leveling and it comes out level. Of course, after that the automatic leveling kicks in at the start of the sprint so perhaps it interprets something different. I'm also concerned about flow and retraction here but usually those are dialed in after temperature and I can't even seem to get that far along. Any help would be appreciated! ABS-tri-tower.3mf

@gr5 This isn't a retraction tower so it's not changing settings; it's standard ultimaker PET-G settings all the way with the one exception of changing brim for a skirt. Oozing happens at a lot of spots. The print bed is often full of little filament dots from the automatic leveling. Then, there's a drag line from the bed front-center to where the print is starting while the filament head is heating after automatic leveling. I'd also offer that the quality further up still isn't great, some stringing and blobs at layer-starts is something I've observed quite a bit. I think your theory might be correct regarding it being hot but I'm just a bit suspicious of something more given that I'm using stock settings and filament which I would expect to be well-tuned lest the forums be filled with issues of poor print quality. I can try turning down the print bed settings or having the fan start aggressively.

Tried it again. Still oozed out a lot at the start and ended up getting caught on the nozzle, again, and pushed around. Retract Tower.3mf

Hi @TimonR -- glad to provide clarity. Printcore is clean externally and I even replaced the silicone gasket. Temperature is defaulted at 240C and I've tried calibrating with a temperature tower between 215 and 260 but there's so much stringing it's really hard to tell what the "right" temperature is. I've tried retraction towers too and while I've had some good luck with stringing with very aggressive retraction, if you'll note the backside of the round-towers, there's some very obvious blobs that don't particularly diminish. That's the start/stop on the z-hop so, I assume, an artifact of more oozing? Everything was printed with bridge-settings "On" I can fire up another retract test if it's preferred. It tends to show some of the worst behavior. For completeness, I'm using models from the Calibration Shapes plugin (https://github.com/5axes/Calibration-Shapes)

Hi @gr5 that's actually a retraction test, so one part with two towers. The reason it's so blobby is because so much material oozes it ends up at a higher Z and the nozzle just starts pushing it around.

Hi. I've included some photos. The filament is *definitely* not moisture saturated as I dried with a print-dry and then printed from a drybox that's loaded with dessicant and has a short-run bowden straight to the ultimaker (with less than a couple hours out of the print-dry). These are a mix of retraction, speed, and temperature towers. The PETG prints on a temp tower as low as 215C (which seems really low). These results are similar for both the transparent (Matterhackers) and Ultimaker branded PET-G.

Hi, I've spend the last couple of weeks churning out calibration prints to no avail and thought I'd come here for ideas before I give up on PETG on the S5 entirely. As stated, I'm getting oozing, blobs and strings with any prints I've tried. Starting with the Engineering - Normal settings on a 0.4mm nozzle I've tried towers and modifications to: temperature retract distance retract speed line width fan speed flow Nothing's been a silver bullet but I'll admit that something is starting to smell "fishy" about temperature. So far, I've tried both MatterHackers Pro and Ultimaker-branded filament and both seem quite happy printing as low as 215C (I've not pushed it further) and I've had problems with PVA burning with this printer before. 215C seems really low for my best quality PETG prints to show up. At this point, I'm curious what steps towards diagnosis would be sane or, does the S5 just do really poorly with PETG?