For whatever reason, I literally cannot complete a single print using the Bambu White PC filament and Bambu PC filament profile on my X1C. Every other filament type and profile prints flawlessly without any stange noises or error messages, including filaments like PA6-GF.
I am using the 0.4mm hardened nozzle and the textured PEI plate, with the filament feeding from the AMS
Somewhere early on in the print, the belt sounds like its slipping or grinding, and makes a very loud strange noise, then the printer starts making grinding sounds and extruding filament in mid air above and to the side of the model, like it experienced a layer shift on both the Y and Z axis. The printer continues to make awful noises and extrude filament into the air until I press the stop button. Afterwards I typically receive an error regarding resonance frequency on either the X or Y axis, and have to retension the belts, clean the carbon rods, and recalibrate the press.
For whatever reason, this only happens with the Bambu PC filament. Every other filament type and profile I have ever used makes absolutely perfect prints. I have no idea why this is happening and am desperate for a solution.
Here are some of the things I’ve already tried.
Making sure the correct printer and nozzle size are selected in the slicer
Resetting printer to factory defaults
Updating to latest firmware (1.08)
Updating to latest build of Bambu Studio (1.9.1.58)
Trying Orca Slicer instead
Performing the recommended maintenance on the belt tension, carbon rods, and lead screws (more times than I can count)
Using the stock PC profile instead of the Bambu PC profile
Printing at slower speeds by using Silent mode
Recalibrating the machine (more times than I can count, and every time after I adjust belt tension)
Changing entire hotend assembly (from 0.4mm to 0.6mm)
Cleaned the nozzle with a small pin to ensure no clogs
Trying gyroid infill instead of the default grid infill
Drying filament at 80c for 8-12 hours
I cannot even print a simple benchy with this material without this exact failure occurring and am at a complete loss as to what is happening. I have not modified any of the preset profiles whatsoever, and have never had an issue with any other material until now.
Very intriguing. Did you ever successfully print with PC or is this roll of white the first you try? I think I’ve only used clear black PC, but that was without drama. I think I have new roll of white, bought a month or so ago, maybe I should dry it and try it.
Incorrectly labeled (or otherwise faulty) filament is not unheard of, but your problems don’t really match that. When you say belts slipping, you mean X/Y belts, right? It’s very hard to imagine why a certain filament would cause that, or in fact any problems other than in the AMS/tubes/extruder/hotend. You seem to have tried anything I would (and more). Did you open a ticket though? Maybe BL can get some clues from the logs. The fact they are encrypted is hysterically ridiculous.
I assume its the X/Y belts as thats the error message I usually see after the print fails, though I have seen the carbon rod message once or twice as well (but not at the same time or with the same print)
This has been my first attempt with any brand of PC, after countless large and flawless prints using various other Bambu filiaments. The weird part is, the quality of the PC print is excellent up until the failure point . Its almost like there is a problem in the Bambu profile or GCode or something, yet it also happens with Orca, regardless of Bambu or generic profile, speed, flow rate, etc. And it happens on any model I try to print, somewhere around the same height typically.
After the failed print, I do the belt maintenance, recalibrate, and can immediately print in a different material without any issues. I have absolutely no idea why it only happens with Bambu PC, though I have admitedly not tried another brand of PC. The only thing I have left to try is to print without using the AMS and see if that changes anything (doubt it will)
Tonight out of curiosity I enabled Auto Recover From Step Loss and that seems to correct the issue of the toolhead extruding off to the side and in mid air when the print inevitably fails, but it does not actually solve the issue of even coming close to finishing a print (even a benchy). The toolhead will stop, recalibrate and attempt to continue the print. However, the awful noises remain, and grow increasingly loud and concerning as the print attempts to continue. After the first instance of failure, the same cycle will repeat every few seconds, where it will print for a few seconds, then make an awful noise, stop, recalibrate, and attempt to continue pritning… until the toolhead doesnt seem to even know where it is anymore. The noises continue stronger and more frequently to the point where I stop the print out of fear of damage to the printer.
I tried to open a ticket but since I dont have an SD card installed and have no video of it happening, I cant submit it. I was hoping to find help here in the meantime if possible. I appreciate you responding, Ive posted this many places and you are the first person to attempt to help.
If the noises only happen with one type of filament or one colour of CF, I can only think of two sources:
The noise is from the drive mechanism as you say, and must be something in the g-code causing this, but then the extruder and gantry must have been driven to their extremes (front, rear, left, right homing limits) for the belts to slip. I don’t see how the belt drive and stepper motor mechanism can cause this if not at the limits, unless there is something in the g-code causing the stepper motors to “flutter” back and forth at very high frequency.
Alternatively, the sound is from inside the extruder due to something unique to this filament not feeding or clogging.
I can understand having to recalibrate after this noise, but I don’t understand why the belts have to be re-tensioned unless there is evidence that they are either looser or tighter.
Similarly, I don’t understand why the carbon rods have to be cleaned unless this event is fouling the rods.
If warning messages are advising this, I suspect they are incorrect and triggered by a resonance anomaly detection.
Do you have some photos and a video of this occurring?
If you export the g-code for PLA and PC into text files and compare them side-by-side (there are many editors/tools online that can do this), can you spot the differences?
Its only happened with Bambu PC filament, admitedly its the only PC filament Ive tried so far with the X1C. Its definitely not a nozzle clog or extruder sound. As to why I retension the belts after each instance of this, its to make absolutely sure they are back to correct tension since the noises are awful and I get the resonance frequency error messsage regarding calibration. In the past I have tried to just recalibrated and sometimes it doesnt remove the error message but performing the maintanence does. I dont clean the rods every time, only if I get the specific error message for it or a month has passed. I rarely print with ABS/ASA so they dont need a ton of cleaning usually.
I dont have video, but someone else just made a thread with a very similar if not identical problem (with video), except they were using ASA or Nylon. Interestingly, I have not had this issue using PA6-GF. I do wonder if the 110c bed temp and 50c - 55c chamber temp is having something to do with this.
Well, after pondering over the thread I linked and being intrigued about the possibility of the belt motors overheating from too high of a chamber temp, I tried a print with the door open and it completely solved the issue. The chamber never exceeded 44c, where as with the door closed it would reach 50 - 55c easily. I had done all my previous troubleshooting with the door closed due to the filament guide specifiying to print with an enclosure.
The printer is supposed to be fine at up to 60°C though. I have printed ASA, PC and PA not only with door + lid closed (they more or less require it), but also with extra thermal insulation and chamber pre-heating. No problem seen. If you are still under warranty you might want to get an SDC, produce logs and open a ticket.
Try modifying a filament profile that works for you to the settings needed for pc. I.e, change generic PETG temps to pc temps and print a test.
I struggled with similar issues trying to print ASA using the Bambu ASA/generic ASA profiles, and had the same issues. Switching to PETG profile and editing the nozzle and bed temp for ASA worked perfectly.