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Shifting, bending and stepping layers on shell model


Teofil
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Posted · Shifting, bending and stepping layers on shell model

Hello,

For the past weeks I started to have an interesting problem printing a shell model with Ultimaker S5. 

The model itself is a airplane fairing modeled in rhino (here is just a part) - the surfaces are smooth, no bends 

model_cura.thumb.jpg.444442f8f1f3ef9698961db29ad734be.jpg

So, first I test printed it in PLA with PVA support - the result was ok-ish with some hard to see bends - however, it didn't matter since it was just a test to see if it fits properly on the plane.

1276247614_bentpla.thumb.jpeg.16b51a9b6f5d5ece7414e94570bc6946.jpeg

The next step was to print it in PETG (Polymaker Tough PETG white) since it will be outside and exposed to the elements. After a first few failed prints with common problems for this material (oozing, stringing), and some weak layer adhesion, I played with the settings and got to a sweet spot. I ditched support entirely since it would get between PETG layers and add to the weak layer adhesion (also, the model prints just fine without one).

However, since then, I haven't been able to print the piece completely. From a certain point on, I either get layer shifting, bending, stepping, or, like in the latest print, all three of them. It's important to note that it doesn't happen in the same spot - it is random.

1887926620_shiftedlayer.thumb.jpeg.f719614cc44aed7fa21c36457003d566.jpeg102935199_shiftedlayer3.thumb.jpeg.3c66e1cdbc795b792e9b2dc211548628.jpeg173347566_steppedlayers.thumb.jpeg.00db28d9c7c88690c3f083c0239c9545.jpeg820703274_shiftedlayer4.thumb.jpeg.e3492f38f4268c5cfbeaff544bd60abf.jpeg615753319_bentsurface.thumb.jpeg.c0802017532e1580204fc9acafed7604.jpeg324098280_sameside_samesettings_differentresults.thumb.jpeg.d06b55029883c83567a4369ebc4a2e65.jpeg1630224441_sameside_samesettings_differentresults_2.thumb.jpeg.9ec09e859aeee4843b0f6d3f9a4b484c.jpeg710790360_shiftedlayer2.thumb.jpeg.af0bec9fb8e849ef1cd0cf7bbb01c921.jpeg

At first I suspected somebody in my office may have *nudged* the printer - however, these errors also appeared when nobody was around. So next I checked the belts, pulleys and axis - these too seemed fine (didn't move, I couldn't tighten the pulleys anymore). Next, I suspected that the temp was too high inside the print box and some kind of warping was occurring, so I lowered the hotbet temp. This too, didn't help. Next, I checked if the walls somehow moved on the bed. Checked, no movement - and now I am out of ideas. Here are my settings for the last print where I have all three problems

 

settings_cura.thumb.jpg.70e7c721191f9a99cbb510d78c4fe71a.jpg

 

For comparison, PLA (black) vs PETG (white) see pictures below. For PLA no layer shifting, just some deformation, for PETG we have both + stepping layers (incline)

3955158_plavspetg2.thumb.jpeg.210dd8d81d3c5e0a1d0545218678e430.jpeg350926901_plavspetg.thumb.jpeg.a3e7e7c2374f42f7a0abddad5d199627.jpeg

I read this post and wondered if there could be an electronics problem also - if so, how could I check? Should I send it to the reseller? 

 

If someone in the community has encountered a similar problem, any help would be much appreciated!

Thank you and have a nice day!

 

stepped layers2.jpeg

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    Posted · Shifting, bending and stepping layers on shell model

    If random, it looks like a mechanical thing, or unstable electronics.

     

    With power off, check if the head moves smoothly and easily, without hard points? Too much friction could also be a cause.

     

    For the belts and pulleys: with a marker pen, write a line from pulley to rod. So you can see if they move.

     

    On an UM2 with SD-card, I would say: check the card and slot for dirt. But I guess the S5 has an USB-slot, that shouldn't cause issues. If via network, maybe unstable connections and data loss? In the old days, when a driver overheated, it could for a moment switch off and cool down. But I haven't heard about that in the last years. If there are cooling fans for the electronics, check if they are working fine? No smell of hot electronics?

     

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