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Printquality issues after E3D V6 + Bowden Extruder
#1
After switching to a E3D v6 Hotend with a NeuStruder bowden extruder setup I use the Make Torture-Test for tuning and benchmark.

Torture Test

The quality of the prints is very bad.
On picture 1 you can see a gap between the flat surface and the (canceled) upper part.
The same problem is noticeable on picture 3. The infill on the Y-axis is not connected to the inner outlines. X-axis seems ok. On picture 3 you can also see gaps between the columns and the flat surface.
Picture 2 shows a flat surface, without any gaps. It still needs tuning, but it prints... ok...

As slicer I use Simplify 3D. My current process settings:
[spoiler]

ABS
Medium

0
0.3
0
0.33
1
1
4.4
0
0
2100
0
0.2
0
5

0
0.2
3
3
2
1
2
0
0
300
0
0
75
98
0.3
0
0
3
3
0.14
85
0
1
0
1
2
4
0
Rectilinear
30
30
100
5
1
1
45,-45
1
0
30
0
0
70
1
0.3
1
1
4
45
0

0
0
0
0
1




0
1
0
0
1





0
1
15
20
0
45
100
0
100
1
0
1
0
0
1
0
0
1
0
0
0
0
0
180.1
180.1
180.1
0
0
0
-1
-1
-1
1
-1
1
G21 ;metric values,G90 ;absolute positioning,M82 ;set extruder to absolute mode,M107 ;start with the fan off,G28 X0 Y0 ;move X/Y to min endstops,G28 Z0 ;move Z to min endstops,G1 Z15.0 ;move the platform down 15mm,G92 E0 ;zero the extruded length,G1 F200 E3 ;extrude 3mm of feed stock,G92 E0 ;zero the extruded length again


M104 S0 ;extruder heater off,M140 S0 ;heated bed heater off ,G91 ;relative positioning,G1 E-1 F300 ;retract the filament a bit before lifting the nozzle to release some of the pressure,G1 X-3 Y-3 F300;,G1 Z+1 E-5 F300 ;move Z up a bit and retract filament even more,G90 ;absolute positioning,G1 Z200 F300; move the platform down 15mm,G28 X0 Y0 F300; move X/Y to min endstops so the head is out of the way,M84 ;steppers off
0
1
Random Song
0

1800
0.5
0.8
0.8
3300
1002
50.3
1
1
1.78
23.95
0
0
0
0
0
20
1
0
1
1
0
3
0
6000
1
12
-0.5
600
1
20
0

190
60
0.9








195
80
1.0






220
80
1.0





0.3
3
3
1
15
25




0.1
4
4
2
30
40


[/spoiler]

I use Repetier 0.92. My Eeprom:
[spoiler]BaudrateDisplay Mode:Light On:Keep Light On:Filament Sensor On:Top Sensor On:Sound On:Filament printed [m]Printer active [s]Max. inactive time [ms,0=off]Stop stepper after inactivity [ms,0=off]Powersave after [ms,0=off]:Temp Ext PLA:Temp Ext ABS:Temp Bed PLA:Temp Bed ABS:X-axis steps per mmY-axis steps per mmZ-axis steps per mmX-axis max. feedrate [mm/s]Y-axis max. feedrate [mm/s]Z-axis max. feedrate [mm/s]X-axis homing feedrate [mm/s]Y-axis homing feedrate [mm/s]Z-axis homing feedrate [mm/s]Max. jerk [mm/s]Max. Z-jerk [mm/s]X home pos [mm]Y home pos [mm]Z home pos [mm]X max length [mm]Y max length [mm]Z max length [mm]X backlash [mm]Y backlash [mm]Z backlash [mm]X-axis acceleration [mm/s^2]Y-axis acceleration [mm/s^2]Z-axis acceleration [mm/s^2]X-axis travel acceleration [mm/s^2]Y-axis travel acceleration [mm/s^2]Z-axis travel acceleration [mm/s^2]Manual-probe X1Manual-probe Y1Manual-probe X2Manual-probe Y2Manual-probe X3Manual-probe Y3Manual-probe X4Manual-probe Y4Z-probe height [mm]Max. z-probe - bed dist. [mm]Z-probe speed [mm/s]Z-probe x-y-speed [mm/s]Z-probe offset x [mm]Z-probe offset y [mm]Z-probe X1Z-probe Y1Z-probe X2Z-probe Y2Z-probe X3Z-probe Y3Autolevel active (1/0)Bed Heat Manager [0-3]Bed PID drive maxBed PID drive minBed PID P-gainBed PID I-gainBed PID D-gainBed PID max value [0-255]Extr.1 steps per mmExtr.1 max. feedrate [mm/s]Extr.1 start feedrate [mm/s]Extr.1 acceleration [mm/s^2]Extr.1 heat manager [0-3]Extr.1 PID drive maxExtr.1 PID drive minExtr.1 PID P-gain/dead-timeExtr.1 PID I-gainExtr.1 PID D-gainExtr.1 PID max value [0-255]Extr.1 X-offset [steps]Extr.1 Y-offset [steps]Extr.1 temp. stabilize time [s]Extr.1 temp. for retraction when heating [C]Extr.1 distance to retract when heating [mm]Extr.1 extruder cooler speed [0-255]Extr.1 advance L [0=off][/spoiler]

How can I adjust my printer to solve this problem. Before the switching to the new hotend it printed just fine.[Image: k-P6090001.jpg][Image: k-P6090002.jpg][Image: k-P6090003.jpg]
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#2
Did you recalibrate your e-steps for you new extruder setup? I forgot to do that at first after switching to a Bowden extruder. Though it was MUCH easier to do, I just disconnected the Bowden tube form the nozzle and measured the filament coming out. Smile
I also had to recalculate all my all my Extrusion Multipliers.
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#3
^^this is most likely the cause.

The other possibility is the nozzle diameter. Without stretching the extruded filament measure the filament output diameter and plug that number into your slicer as the nozzle diameter.

Kieth



Kieth
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#4
Well, the e-steps are calibrated.
Maybe I got a wrong nozzle with the hotend, I will check that first
Reply
#5
Alright following solution:

changing Nozzle Diameter from 0.30 to 0.40 (this was the main problem), extrusion width to 0.42 and extrusion multiplier to 1.14. Now I only need some fine tuning and the prints are quite nice.
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#6
ALright, next problem:

The print sticks to the heatbed very well and thin walls print out alright. But when I got a part with infill it deforms very much. You better check the pictures. They say more then 1000 words. What could be my problem?[Image: IMG_20150619_170440024_HDR1.jpg][Image: IMG_20150619_170446748_HDR1.jpg]
Reply
#7
Looks to me like your temperatures are off. Also, consider reducing the infill %, perhaps reduce the bed heat after the first layer.

Kieth
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