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Massive extrusion jumps and errors midway through gcode, BUG??

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Posted · Massive extrusion jumps and errors midway through gcode, BUG??


I'm relatively new to the 3D printing scene and have been going through the learning process of setting up my first printer and printing a few of my engineered parts/ etc. I'm very familiar with scripting and have found my issue in the gcode, and is not a firmware or mechanical problem on the printer.  I'm using Cura 3.2.1 and been having an odd issue where, on particularly large prints, the absolute extrusion value will be defined to some extremely far off value and then proceed to eject all the filament, just for it to continue that section of code (for example an inner wall) - then finally return back to the extruder value where it should have been working off from. This results in huge retractions (which i had OFF in cura, retractions were disabled) and then also where the filament re-catches...extrudes meters of filament just to "catch up" resulting in a blob of where the event occurred. Sometimes the retractions and "catching up" happens in reverse order. See pictures:

(Find "Z144" and scroll down in Gcode)

Is this a bug? I've tried various settings and this happens on different models as well. I've tried with and without retractions as well as combing On/Off.

Layer view looks normal and also inspected at the affected layer with playback:





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Posted · Massive extrusion jumps and errors midway through gcode, BUG??

I think I found the issue for the record if anyone experiences this again:

I tried different versions of cura:
It seemed to be an issue with the how the model was made. If there is some excessive amount of internal geometry, then the slicer cannot interpret the model properly and I guess this is just the symptom. The best indicator of when this was the problem is if the supports generate through the model unexpectedly or even show up in a layer that is not the "active layer". What I mean by that is if you were to scroll through layer view you would see a support at layer (say 359) pop up at Z height 0.1. For me, I had some bosses and hole cutouts that had excessive geometry line between the boundaries. However, the symptom may affect a completely different location than where the bad geometry is located. 

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