Material stuck in print core after each print

[LXXXIII 0]

Hello,

 

The past year I printed sporadically with my UMS5 (Pro Bundle) machine. All this time without any issues.

In the last 3 weeks I ramped up printing to almost 24/7. Shortly after this I encountered more and more 'The material seems to be stuck in print core 1' errors after each print. At this point it's happening after each print. When completing the wizard and removing the stuck material I can't seem to notice why the material is stuck. The end of the material looks normal when I inspect the ejected material. At the area where the material was in the feeder I can see some grinding damage.

 

I regularly perform maintenance on the machine, following the Ultimaker instructions. This includes cleaning the print cores (hot and cold).

 

The machine runs the latest firmware and I'm using Cura 4.13.1.

I'm using a CC 0.6 print core and am printing Fillamentum Extrafill PLA. (I tested with Ultimaker PLA, this also results in stuck material)

 

Any input on how to solve this issue will be appreciated.

[Dustin 84]

Sorry to hear you are having issues.

I would recommend updating your version of Cura.
Additionally, can you confirm the exact firmware version number you're on?

Doing a quick glance at the Support Knowledge Base also notes printing with materials such as PLA with a CC core is considered experimental. So, your results may vary considerably. 
CC print core compatibility (makerbot.com)
Print core and printer compatibility (makerbot.com)

[gr5 2,094]

Dustin I doubt it's the version of Cura.

 

LXXXIII - there are many possible causes.  The most common by far is that the front fan stopped working.  The printer doesn't have a way of knowing this.  The 2 symptoms is low or failed extrusion after 5 to 20 minutes of printing and having trouble getting the filament out of the print core after it has cooled.

 

So heat either printcore to 100C and as it passes around 40C the fan should start spinning.  Open the front cover to make sure it really is spinning.

 

If that works then it's most likely a problem with the printcore.  The teflon inside after a lot of use can have issues where there is now a space for the filament to expand into, then cool/harden, then get stuck.  Printcores are considered expendable (like filament) and should be replaced occasionally.

[LXXXIII 0]

I've tried switching to Cura 5.2.1. But for some reason I can't get the same results with the particular model I'n currently printing compared with slicing in 4.13.1

 

I know the CC print core is not really designed for printing PLA. But what's the alternative if I want to print with a 0.6 nozzle?

 

The S5 is on firmware 7.1.3

[LXXXIII 0]

14 minutes ago, gr5 said:

Dustin I doubt it's the version of Cura.

 

LXXXIII - there are many possible causes.  The most common by far is that the front fan stopped working.  The printer doesn't have a way of knowing this.  The 2 symptoms is low or failed extrusion after 5 to 20 minutes of printing and having trouble getting the filament out of the print core after it has cooled.

 

So heat either printcore to 100C and as it passes around 40C the fan should start spinning.  Open the front cover to make sure it really is spinning.

 

If that works then it's most likely a problem with the printcore.  The teflon inside after a lot of use can have issues where there is now a space for the filament to expand into, then cool/harden, then get stuck.  Printcores are considered expendable (like filament) and should be replaced occasionally.

I read in other posts about issues with the fan causing a similar issue. I already checked. The front fan is working properly and there is also no debris blocking air flow.

 

I also suspect it's the print core that's causing the issue. What's the expected lifespan of a CC print core? I'm at 16 days right now. Doesn't seem that long.

 

What's the alternative to a CC 0.6 print core if I want to continue printing at 0.6 nozzle size?

[gr5 2,094]

3dsolex.com has printcores from 0.1mm (yes!  very tiny) to around 2.5mm including 0.6.  They have changeable nozzles so you can try .4, .6 and .8 with one printcore.

 

Maybe you got a defective CC 0.6.  I really don't know.  is it a "CC 0.6 red" or a regular "CC 0.6"?  (or is there only a regular "CC 0.4"?)?  I've lost track of the CC printcore varieties.

 

The CC 0.6 should work fine with any filament that an AA 0.4 will print.

 

I would do some cold pulls (google if you don't know what this is) on a working core like an AA 0.4 and on the CC 0.6 until you get a really nice shaped tip with the narrow end included.  Then I would examine the diameter of the pulled filament with calipers and maybe insert it cold back into the core to see how tight it is.

 

The issue that can happen is that the teflon tube which is basically inside the aluminum fin section, can either be too large such that if the material melts in that cooler section and gets thicker, it can cause a clog where it won't go down through the heat break and it won't go up through the top of the core.  OR it can be that the teflon tube is too short and there is a gap of air just above the heat break and molten filament can get in there and cool and get stuck.

 

After "broken fan" this is the most likely cause of materials stuck in a core.  I really don't know.  It could also be the flow sensor I suppose?

 

Did you make sure you have "line width" set to 0.6?  For a CC 0.6 core printing PLA I would probably use an AA 0.4 profile (they are better debugged) and set the line width to 0.6 and then when you go to print it will say "wrong printcore" or something and you can hit "ignore".

 

But really it seems to me the problem is most likely with the printcore but that sucks as that's the most expensive core.

[LXXXIII 0]

It's a regular CC 0.6 core. Only printed PLA with it.

 

I already came across the 3dsolex website in my troubleshooting search.  I've now ordered an AA printcore from them with 0.6 nozzles.

 

During regular maintenance I do a hot and cold pulls. The print core is always as clean as a whistle. Once the 37h print that's running is complete I will do some cold pulls on the 0.6 and a 0.4 nozzle. I will share my findings.

 

The fan is in my case not the cause of the problem. Its working fine.

 

The line width is absolutely set to 0.6. I'm printing a model that's designed with a 0.6 in mind.

[gr5 2,094]

It's not about how clean the cold pull is.  It's about the shape - does it bulge out?  More than the AA core?  That bulge can get stuck and cause underextrusion, no extrusion, or it might work fine during printing but then you can't get the filament out of the printcore.  You posted screenshots of error messages but I'm not familiar with that exact error so I'm not sure if the failure is during printing or after printing is complete.  I'm guessing it's the flow sensor that is noticing a problem.  Sometimes the flow sensor is just plain wrong.  You can view the flow sensor results while you are printing.  Go to the url of your printer's ip address and look at that page and there is a link to the temperature graph which includes flow sensor data.

[Enigma_M4 105]

Hi,

probably the culprit is your feeder.

Is the feeder clean inside (afaik maintenance shedule recommends cleaning every month) and is the feeder tension set properly?

Regards

[gr5 2,094]

If you don't have the material station then it's easy to test the feeder - you fight it when the filament is not yet in the printer head.  It should take around 10 pounds force to be able to pull the filament backwards when the feeder is trying to pull the filament forwards.

 

Since I think you *do* have the material station I'm not sure how to do that test.

[Pflueger1018 1]

Hi @LXXXIII

i have exact the same Problem with my Printer.  I print ABS with a AA0,4 Nozzle. After each print the Printer stop and sad that the material is Stuck.

I cleaned the feeder , bought a new nozzle , cleaned the fan, set the tension of the Feeder but its always the same Failure.

Did u find a solution for the Problem?
 

[Cruzzer08 1]

I am having the same problem, its driving me crazy!

The entire print goes fine and at the end I get that same error screen,

The wizard has me remove the bowman tube which comes out with very little resistance, then forces me to waste about 2 feet of filament every time.

I've tried increasing standby temperature, and that didn't help. I've done print head cleaning multiple times, fan is working. Removed material tip looks clean and well shaped but there is a section above that is thinner. 

 

What is the machines print head process when a print ends? Does it allow the filament to cool too much before material handler extracts? is that controlled by print temperature or standby temperature? Is there a sensor that has to see the filament at a particular location before extract? It does only happen with the PETg ESD, is there a material setting that I'm missing, the prints come out great. I did get the print profile from the Ultimaker Marketplace. 

 

Ultimaker S5 w/material and air handlers,

Firmware 7.1.3, Cura 5.2.1

AA.04 printcore, using PETg 0800 ESD

[Dustin 84]

3 minutes ago, Cruzzer08 said:

I am having the same problem, its driving me crazy!

The entire print goes fine and at the end I get that same error screen,

The wizard has me remove the bowman tube which comes out with very little resistance, then forces me to waste about 2 feet of filament every time.

I've tried increasing standby temperature, and that didn't help. I've done print head cleaning multiple times, fan is working. Removed material tip looks clean and well shaped but there is a section above that is thinner. 

 

What is the machines print head process when a print ends? Does it allow the filament to cool too much before material handler extracts? is that controlled by print temperature or standby temperature? Is there a sensor that has to see the filament at a particular location before extract? It does only happen with the PETg ESD, is there a material setting that I'm missing, the prints come out great. I did get the print profile from the Ultimaker Marketplace. 

 

Ultimaker S5 w/material and air handlers,

Firmware 7.1.3, Cura 5.2.1

AA.04 printcore, using PETg 0800 ESD

Sorry to hear about the issue your having.
I would not increase standby temperature from a Marketplace profile.
What profile are you using exactly? And is your material the same brand? or are you just using a similar material from a different brand?

Why this is important and to answer your question..
The machine has multiple steps to the end print process basically "yes" to all your related questions to that. Each Marketplace profile has to be tuned manually for that process before its published.
So a Marketplace profile being used for a different brand of material, it is indeed possible it wont work completely during the end print stages.

Though issues like this still usually point to hardware issues.
Have you contacted UltiMaker support about this issue by chance?

[Cruzzer08 1]

On 1/26/2023 at 10:28 AM, Dustin said:

Sorry to hear about the issue your having.
I would not increase standby temperature from a Marketplace profile.
What profile are you using exactly? And is your material the same brand? or are you just using a similar material from a different brand?

Why this is important and to answer your question..
The machine has multiple steps to the end print process basically "yes" to all your related questions to that. Each Marketplace profile has to be tuned manually for that process before its published.
So a Marketplace profile being used for a different brand of material, it is indeed possible it wont work completely during the end print stages.

Though issues like this still usually point to hardware issues.
Have you contacted UltiMaker support about this issue by chance?

I am using the exact material from the Ultimaker marketplace, Jabil PETg 0800 ESD

There was a recent update to profile that I have not tried yet. Notes only say that it is for S7 support but I will get it loaded and give it a try today.

I have not contacted support yet. I'll try todays print with the profile update and original settings. If the problem remains I'll contact Ultimaker. 

Thanks for the Response

[arj3090 2]

I have this exact same issue that seemed to have started when I started using 3DXTech ASA. Every time a print is finished I have to:

 

- Turn off the printer

- Turn it back on

- Manually heat the print core

- Pull the filament out

- Cut off about 10mm

- Do an Unload on the print core

- Unload the material station

- Reload and select type

[jirodriguez72 18]

I have this same issue with NylonX and NylonG using the .6 CC Ruby core, used to not have any issues, but about 5 or 6 firmware updates ago it started having this issue and I have not been able to get it to go away....very annoying considering the cost of S5 Pro bundle.

[Dustin 84]

1 hour ago, jirodriguez72 said:

I have this same issue with NylonX and NylonG using the .6 CC Ruby core, used to not have any issues, but about 5 or 6 firmware updates ago it started having this issue and I have not been able to get it to go away....very annoying considering the cost of S5 Pro bundle.

Have you reached out to MatterHackers for help with this issue?
 

[mrender 21]

3Dsolex do some great alternatives to the Ultimaker consumable cores.  All the bits on the 3Dsolex are replaceable unlike the ultimaker ones. Great customer service too which is good to know.

Printcore CC 0.4 Everlast Ruby – 3DSolex