Corrupted Gcode with long prints when using USB on Ultimaker 3 Extended

[NLR 0]

I have run into an issue when printing large products on our Ultimaker 3 extended. I have done some troubleshooting myself but I cannot find the cause.

I generate the gcode file with Cura 2.5.0 (roughly 170mb). as a check I load the file in Simplify3D all looks well.

I copy the file over to a USB stick with more than enough memory on it, then load the file from the stick into Simplify3D to check again, all is well.

I remove the USB stick from my PC (even using safely remove hardware in windows) start the print and somewhere during the 20+ hours the printer stops, and claims that the job is finished even though it is not.

What I found so far is that once I try to open the gcode again (load from the USB stick) Cura refuses to open it gving a "failed to read Gcode" error, and simplify3D shows the model as it has been printed (cut off). I even delved into the gcode by opening in notepad and indeed it seems as if the second part/half of the print is no longer present in the Gcode.

I have tried several USB sticks but I run into the same issue, it only happens with files > 100mb

Has anyone else run into this issue? What can I do to solve this, as it has cost my quite abit of filament on sailed prints so far.

[Marco_TvM 34]

Would it possible to send the printer logs of a recently failed print?

Use something like WeTransfer to get us a link to investigate.

[NLR 0]

Log file of the failed print can be found here https://wetransfer.com/downloads/0311382fd935e2a8162cada2fa55397220170814102353/fd1147d758315b7523bfc387efb194db20170814102353/13bc6c

Aug 02 07:46:36 ultimakersystem-ccbdd3001bb7 python3.4[436]: 2017-08-02 07:46:36,699 ERROR gcodeFileHandler Error accessing file 'UM3E_Funnel_print_2_1.gcode' at line 1326052.

Aug 02 07:46:36 ultimakersystem-ccbdd3001bb7 python3.4[436]: Traceback (most recent call last):

Aug 02 07:46:36 ultimakersystem-ccbdd3001bb7 python3.4[436]: File "/usr/share/griffin/griffin/printer/fileHandlers/gcodeFileHandler.py", line 56, in run

Aug 02 07:46:36 ultimakersystem-ccbdd3001bb7 python3.4[436]: line = f.readline()

Aug 02 07:46:36 ultimakersystem-ccbdd3001bb7 python3.4[436]: File "/usr/lib/python3.4/codecs.py", line 313, in decode

Aug 02 07:46:36 ultimakersystem-ccbdd3001bb7 python3.4[436]: (result, consumed) = self._buffer_decode(data, self.errors, final)

Aug 02 07:46:36 ultimakersystem-ccbdd3001bb7 python3.4[436]: UnicodeDecodeError: 'utf-8' codec can't decode byte 0x80 in position 25: invalid start byte

Aug 02 07:46:36 ultimakersystem-ccbdd3001bb7 python3.4[436]: 2017-08-02 07:46:36,710 INFO faultHandler warning(, Error while reading file 'UM3E_Funnel_print_2_1.gcode', 28, {'file_line_nr': 1326052})

Aug 02 07:46:36 ultimakersystem-ccbdd3001bb7 python3.4[436]: 2017-08-02 07:46:36,746 WARNING faultHandler added Fault: L:WARNING C:FILE_ERROR M:Error while reading file 'UM3E_Funnel_print_2_1.gcode'

Aug 02 07:46:37 ultimakersystem-ccbdd3001bb7 python3.4[436]: 2017-08-02 07:46:37,556 INFO timeEstimator Print job statistics {

Aug 02 07:46:37 ultimakersystem-ccbdd3001bb7 python3.4[436]: "print_time": "15:39:25.267077",

Aug 02 07:46:37 ultimakersystem-ccbdd3001bb7 python3.4[436]: "original_estimate_in_seconds": 175159.0,

Aug 02 07:46:37 ultimakersystem-ccbdd3001bb7 python3.4[436]: "filename": "UM3E_Funnel_print_2_1.gcode",

Aug 02 07:46:37 ultimakersystem-ccbdd3001bb7 python3.4[436]: "original_estimate": "2 days, 0:39:19",

Aug 02 07:46:37 ultimakersystem-ccbdd3001bb7 python3.4[436]: "print_time_in_seconds": 56365.26707662

Aug 02 07:46:37 ultimakersystem-ccbdd3001bb7 python3.4[436]: }

[simonrafferty 0]

I'm having a similar issue with my (week old) U3.

A long print (20h) aborting 10mins from the end when printing from USB. There is no WiFi here - so I cannot use it instead.

Having had this three times and last time discovering the GCode was corrupted, I checked it before I started the print. After the print aborted with Error code 1043543, the GCode now includes this block:

G1 X137.238 Y131.708 E336.74435
G1 X137.238 Y145.687 E336.81009
M204 S5000
M205 X30 Y30
G0 F15000 X137.244 Y146.027
M204 S1000
M205 X10 Y10
G1 F1500 X136.402 Y146.179 E336.81412
G1 X135.56 Y146.026 E336.8 @Š    À& @ŠA‚;€3LС|0†² 0{MØ0‡òñÑ7ŠÌgƒ0MEí‘A=á…{Ú°@Øè5MÀÌÑ«¤(o\-5P¦aTMFÁ»¸A`*€`8õÒš§6;±M^\r
)Kp†idêÅáIâ.RIâ€PB¿q•·n‘·â4*<ÁH
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Iš¼špÚÑÆø:N¡ÌK¦Og€ýp¾×mYï‘Úž($m®ÄÎNa¯?×®ž³Ö‰ëŸ C†.kqLõÝâ@‹š°z_¼ìa0˜´ü"×ÀÕê4îþ¤¯Q†ÂµÅ•ÐÞe‚퉓Aø£ºn'àÕˆ›0¨qó1ˆ¹°1ßðúC³	ãí0!´û€H4‘ NŠ    ’& NŠŽ;$5LbZ}0¬«² ¾KXØxiõñ#p,ÍÒy¹0’šö}“
á—£|69@æiÚnåÀhÑ}4̾W·ýP_÷þ¡ò©Á•"z@ÝJì`Æ(ˆŒ…R±ŸeXZÚýp[ô-üÂ+8¡[Q±6È„x€^ÄcÕÁ‘‰Ø µ<´—¯$héÙIÍ4‰È ®ÄSˆä	q;†èœÅ è°{ÝŸ¢Ïq‚a?ú]7¦ˆDÀ¶©ŸüûaQµñ˜„m?П)öÁr\PA]pl-Y”«àv•Zê–!z1÷ÁN›N‚ð{]J’	õ!Cz8Oíø ï)OÅ^Îu£q­fÛ“{¨ž§ñÕ©Mï&f ‰óö¦ñÒEq‘J¯0\„”XgŠáfÁ¬ÜŒ’'@UϧWþÑlûÕbÜwP`»‰›V7Á¤úmsÏÂ`§¯
%h"|±ÎJÍ‹Á³Spbâ%Ó´¡ª¿n®TÁŸ€ÿ:}Ù Ë‘øtV>lacÚ8P*)xÎüØCUz Ð7rÍ'qêw1åÀ"%°¼æÞ7^aez¿™oÀ×ë+™7\Q¤Ñ’¹SmÐ Hš0&°úAlA
©ÝšJàWÕ™(iTi1&€AÇÅð<‚4 ¹0š!’¡ó]=Y5
G1 F1140 X136.835 Y143.319 E337.46441
M204 S5000
M205 X30 Y30
G0 F15000 X136.835 Y143.814
M204 S500
M205 X5 Y5
G1 F1140 X135.966 Y144.683 E337.47115
M204 S5000

Then continues to the end of the print.

Did you reach any conclusions about NLR's query? Is the solution just to use WiFi or avoid long prints?

Would it help if I set the file to read only? Does the U3 pay attention to the RO Flag? Is this more likely a hardware issue?

Any ideas? I'm getting bored of failed / aborted prints! Apart from that, the U3 is fantastic.

[Marco_TvM 34]

Have you tried a different USB stick?

Allways make sure to cleanly eject/unmount the USB stick before removing it from the PC/Mac.

[CarloK 203]

Most likely your USB stick has a few bad sectors. Over time this happens to all USB sticks and memory cards. Good quality brands just take a bit longer to fail.

Software exists to scan your USB drive for these errors and mark those sectors as bad. But, since your prints are way more expensive and time consuming I would suggest to buy a new USB drive. Just get the smallest size you can find, even a few Gb will do.

[robinmdh 100]

I would suggest to buy a new USB drive. Just get the smallest size you can find, even a few Gb will do.

Agreed, or just print via network, you can use the wired network if you don't have WiFi.

Combined with Cura connect network(WiFi or Ethernet) printing is a lot more attractive, IMHO.

Edited December 6, 2017 by Guest