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Ultimaker S5 feeder problems and grinding


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Posted · Ultimaker S5 feeder problems and grinding

After several months of lobbying, I was able to finally purchase Ultimaker S5 printers for the workplace.

 

Now, it's one problem after another.  This wasn't the trouble free printing experience I had envisioned.

 

We received these printers a few weeks ago and just started doing basic test prints, to tech the students.

 

Printer One keeps having an issue grinding into the PVA material.  Or not feeding at all. 

We frequently have to manually "move" material for the prints to print with material.  The feeder tension is set to the middle position and I'm still seeing these grinding issues.

 

Printer Two is even worse.  Feeding filament into extruder two is nearly impossible.  Filament doesn't smoothly pass through.  It takes a few pushes to get it into the Bowden, which just leads to a ground up filament segment if we attempt to move the material or print.  I've had the extruder cover off, referred to the manual and I have 6+ years of experience with Ultimaker UMO/2/2+ printers.  I don't know what's messing up that extruder but it's clean, no debris...and just not right.

 

I know PVA is tricky and brittle, but no matter how much we change the tensioner, it's grinding and again, that feed from extruder to bowden seems compromised.

 

I've reached out to Support and hopeful they can offer some advice I haven't thought of.

 

Have others had issues with their feeders?   I thought I would inquire with the community while awaiting a response.

 

I spend a lot of effort promoting the ease of use of Ultimaker at work.  Now...I'm pretty red faced.

 

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    Posted · Ultimaker S5 feeder problems and grinding

    Hi @LePaul, thank you for your message and for lobbying for the Ultimaker S5! 

    Printer one only has troubles with PVA, or also other materials? Do you preserve the PVA in anyway, either prior or during printing? 

     

    Printer two; did you try different types of filament? (Old?) and new? Could you perhaps share a picture of your feeder, potentially with the cover off if you mention you had it off before? I'm not sure what I would be looking for, but perhaps something catches our eye. Thanks! 

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    Posted · Ultimaker S5 feeder problems and grinding

    One has only tried PVA that came with the printer.   It's working now....but we had to play the "move material" game to get material to flow.   Not the normal process.

     

    Again, only new filament...what came with it and the 40 rolls of UM filament from PrintedSolid.

     

    Picture coming

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    Posted · Ultimaker S5 feeder problems and grinding

    I think one thing I found is the collet piece holding the bowden into the extruder has some play.  So there may be some misalignment there causing friction.  I just put it together again but left a bit of filament in the extruder as a guide to getting the collet/bowden to align/fit right.  I cleaned out some more debris before putting it all back.

     

    More testing

     

    image.thumb.png.7e938514f1f628ab3331804acf7dc272.png

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    Posted · Ultimaker S5 feeder problems and grinding

    Well, as soon as I had it back together, it's a struggle to get that filament to slide into the extruder.  Back to where I started

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    Posted · Ultimaker S5 feeder problems and grinding

    Can you push the filament so far into the Bowden tube that you see about 5cm of it? I always load it that way, then you don't have to wait funtil it comes out of the print core.

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    Posted · Ultimaker S5 feeder problems and grinding
    10 minutes ago, Dim3nsioneer said:

    Can you push the filament so far into the Bowden tube that you see about 5cm of it? I always load it that way, then you don't have to wait funtil it comes out of the print core.


    Same here.   But that’s the issue.  Pushing the filament into the extruder isn’t smooth.  There’s something about how it’s connecting to the bowden tube that seems problematic. It can take several shoves to finally get it in there.  But that leads to the failure and grinding 

     

    Only using new PVA that came with it

     

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    Posted · Ultimaker S5 feeder problems and grinding

    If not done already, check if the Bowden tube is mounted the correct way round.

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    Posted · Ultimaker S5 feeder problems and grinding

    I personally always cut a point on the end of my filament when i load it, it makes it so much more easy to load than a flat end. Grinding with PVA can come from it being wet, PVA can get wet very fast going by the type of place its in.

     

    So i would dry it out 65C for 4-8 hour should do it and then put it in a polybox or some other airtight system, even when in use.

     

    IMG_9814.thumb.JPG.a0ce52aaa42ce623437a0d56dbdcd43f.JPG

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    Posted · Ultimaker S5 feeder problems and grinding

    I've been working with Erin over to support on this.

     

    To update, I've done some cold pulls on the BB hot end and the first one had a lot of PVA stuck to it.  The second came out clean.

     

    I reloading the PVA and it was trickling out of the hot end.

     

    This morning I had a student start a print with support and nothing is coming out the PVA side.

     

    Still working through some ideas.

     

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    Posted · Ultimaker S5 feeder problems and grinding

    as you said... PVA is tricky... (it may vary depending on the brand though...)

     

    I always remove the PVA from the printer (if i don't need it immediately again), and feed some cheap PLA through the BB core (just with the normal "load material" function). This removes any PVA residues from the print core and is much more easy and gentle than those hot/cold pulls (IMHO). I never had a clogged BB core since i use this method (no matter how long it rests unused in a drawer).

     

    I guess any leftover PVA will slightly expand in the nozzle when it absorbs moisture and then simply clogs, if it is reheated again...(but that's just my simplified theory)?

     

    Oh - and double check if the feeder is correct reassembled - especially take sure that this screwhead is back inside the housing.

     

    grafik.png.e279742bdca0ac5962a84a7f35c3122a.png

     

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    Posted · Ultimaker S5 feeder problems and grinding

    Screwhead is inside, thanks for that reminder.  It always makes that un-nerving SNAP when you open the feeder.

     

    I think I have narrowed it down a bit more.  When feeding filament in, it doesn't seem to always hit the hole in the level to glide into the bowden.  It definitely takes some finesse to get through there but it seems like more than usual.

     

    With the cover off, we can see how it should work.  

     

    With the cover on (tension screw under the cover), we tension it to the middle position, per the service manual.

     

    This last time, we loaded PVA and heard a SNAP sound, and it broke the PVA in the tube.  There was a few inch gap between the two segments, so we used the Move process to push them together.

     

    Side note, is there a way for the PVA extruder to do the prime blob as the primary one does at start of print (we checked that on in Cura)  I know we can do a prime tower but that's overkill.

     

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    Posted · Ultimaker S5 feeder problems and grinding

    Interesting...we're seeing that the PVA is trying to prime off the side of the bed?  How could that be fixed?

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    Posted · Ultimaker S5 feeder problems and grinding
    21 hours ago, LePaul said:

    Side note, is there a way for the PVA extruder to do the prime blob as the primary one does at start of print (we checked that on in Cura)  I know we can do a prime tower but that's overkill.

     

     

    Yes, it can do a prime blob just be sure you click on that print core at the top of the settings to swap the settings over to that print core.

     

    509637293_Screenshot2020-02-22at12_45_55.thumb.png.23b6fdd4f5a375daac714b40b5cea079.png

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    Posted · Ultimaker S5 feeder problems and grinding

    Perfect, thanks!

     

    It looks like a bad roll of PVA is the cause of my issues.  But to be sure I have taken Erin's advice to install an AA core, load some PLA and do a print from extruder two.  That's next!

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