Extruder gear stuttering/skipping

I have a P1P (4 actually) and on this particular machine extrusion is not working properly. The yellow gear stutters/skips and as a result the filament it not extruded properly.
-This is not a case of a clogged nozzle. I have replaced the nozzle.
-I took apart the extruder and made sure that all the gears etc were clear.
-I replaced the extruder motor but unfortunately that did not solve the issue.

The reason I tried replacing the extruder motor was because of this thread with a very similar problem.

Any other ideas? Of course I have created a trouble ticket with Bambu but they are SLOOOOOOOOWWWWW to respond.

I went ahead and ordered the two PCB boards that are present on the tool head.

Grabbing at straws, could it be the filament cutter not fully retracted?

Interesting thought. I removed the cutter and tried again. No dice.

I have now also replaced the Extruder unit and there is no change. Still skipping and inconsistent filament extrusion.

Figured someone smarter than me would have replied by now. The only thing I can think of is something is restricting the filament.

If it were me, I’d pull the nozzle and manually feed the filament like when you load from the external spool holder and see if it’s being restricted somewhere. If you can feed the filament manually thru to the extruder, then manually spin the extruder to confirm you can feed it thru the extruder.

Failing that, it has to be something in the nozzle. Or, if it only happens when feeding from the AMS then you’d need to confirm the filament pathway between the AMS and printer. Not sure what configuration you’re using here. IE, using AMS or the external spool.

Something to try while waiting for BL…

Nothing is constricting the filament. I put a new extruder, new extruder motor, and new nozzle on and the motor still stutters. Without a nozzle on at all, and therefore no resistance on the filament, I can advance filament through the extruder but the motor still stutters. I’ve read about the PCB board soldering joints coming slightly loose and causing an intermittent connection so the only thing left for me to try is replacing the two boards and cables in the toolhead.

I finally received a reply from Bambu support and it was clear to me they had not read my issue or my replies carefully. The sent me a link to try and identify the source of the “clog” even though I repeatedly said that there was no clog anywhere. Sigh…

Check the usb connections at the ap board ; it links the data to the th board.

Do you have a usb c cable you can test with or swap with your other printer ?

Replace the USB-C cable

I also just seen you have NOT changed the th board for driving the extruder motor my first time reading this post I would swap th board and usb c cable at the same time so you can eliminate them parts with your other printer.

Just check to see what th boards you have on the other printers single blue or dual red lasers.

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Ok now I’m just dumbfounded. Somehow the machine started printing normally again, no motor stutter, and I have no idea why. I decided to just tinker with it again and double check things and somehow the issue resolved itself. I’m going to note what I did, but I really have no idea what changed.

I started by examining all the wire connections to make sure they were all seated properly. After I confirmed that, I started by disconnecting and removing the outer fan case, disconnected the thermistor and heating element wires, and disconnected the hot end fan. I then turned the printer on and, using the panel controls, started feeding filament through the extruder. I noticed right away that I did not see the motor stutter. So I put one component at a time back on and kept testing with each new component. The last component I put back on was the nozzle and there still was no motor stutter during extrusion. All of these things were the same as before.

I have now printed several models and all have come out perfectly. I simply have no idea what changed. I was extremely careful in all of this to make sure that the cables were all seated properly and there were no loose connections anywhere. My best guess is that there was something interfering with a cable connection somewhere that got cleaned out when I removed and reseated the cables. Hopefully it lasts!

Well the good new you are working again :grinning:

  • You might have had just a poor connection then :crossed_fingers:

  • I would have the usb c cable as a backup option because they are bending around all the time in the cable chain.

Thanks for the updates

Well, after several successful prints the problem started again. Attached is a pic of what I get when this starts to happen. Even though filament can flow through the nozzle, the stuttering of the motor results in inconsistent extrusion. Support is sending me a new extruder motor…even though I mentioned a few times that I have already replaced the motor and it didn’t solve the issue. The only thing I haven’t replaced yet is the PCB boards in the toolhead and the cable that connects those two boards, which arrive today. If that doesn’t fix the issue I don’t know what to do. I love these printers (I have 4 P1Ps, 1 X1C, 1 P1S) but support has been less than helpful.

Hey there, I recently started having the same issue. I noticed that if I push the filament in it works fine but without aiding it, it will only work for a bit before it starts stuttering and exhibiting the same issues. I took apart the extruder unit and noticed the yellow extruder gear, which I have replaced for the hardened steel set; has quite a lot of play in the bearing it seats in. When assembled if I push filament through the extruder, I can see the yellow gear noticably deflect, and my assumption is that this deflection is causing just enough space to allow the yellow gear to slip on the extruder stepper motor. I’m not sure if this is my actual issue as I haven’t ordered the parts to replace and test yet, but it also sounds like you already replaced the extruder unit, which I would assume would fix this issue. Have you had any updates on it? If it’s something else happening I would like to know as well. Thank you and good luck.

This has proven to be quite a mess and I can’t point to a definitive problem. Over the last few days the printer has been printing fine, and I have no idea why. Then today I had a failed print and noticed there was no filament being extruded (clog). I assumed it was a clog in the nozzle so I cleaned that out so filament could flow through. It was in that process that I saw that the filament would only consistently push through the extruder if it helped feed it through. Mind you, this was the NEW extruder that I had put on recently to try and troubleshoot this issue. I noticed that if I manually tried pushing filament through the gears would slip on the filament with just a little bit of resistance. So I put the OLD extruder back on and there was no more filament slipping and the machine prints normally again.

My 3 other P1P printers have been fine but this one has been a lemon for sure.

I had a similar issue and it turned out to be the clips on the filament tube were too tight effectively pinching the tube too tight and not allowing the filament to move at the speed the extruder needed. Hope you get it fixed.

Just a heads up from someone who had the EXAKT same Issue.

Printer delivered, made ready, firmware update, calibration first prints worked fine.

Then regularly failing prints. After failed print the extruder keeps making clicking noises, NO manual extruding possible due to motor making horrible squeaking noises like a needle PRINTER.

So i checked the Extruder, no issues.
I Checked the nozzle including making cold pulls, NO issues.
Changed the Filament from PETG to PLA, Regular Printing Fails.

So i got a replacement Extruder, all hopes were up, STILL REGULAR FAILS.
So i changed the nozzle to .6 AND? Still THE SAME ISSUEs.

BUT ! i found my Problem guys.

TL:DR

Check ON THE PRINTER ITSELF under Settings>accesories>Nozzle
What nozzle is selected? Mine was 0.2 so i changed to 0.4 and the Problem was SOLVED.

F me and F Bambulab for delivering EVERY Printer with a 0.4 Nozzle but mine with a 0.2 Setup.

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Just to Add after failing Prints, and repowering i could manually extrude.

Wow! That’s the first time i have heard of that. I thought alot about your problem. But everyone gave you good advice. Never thought of checking nozzle size in firmware.

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I still haven’t been able to pinpoint the root cause of this, but I suspect there was a cascading error. When one part failed or clogged it affected the other parts of the system. After replacing the nozzle (twice), extruder (twice) and motor it is printing fine now.

I still have the exact same issue.

I ve swapped the extruder, the nozzle, and now i have swapped the motor and i still got the same issues.

i have contacted paypal due to bambus slow responses and i am not willing to replace every freaking part of this Printer.

What type of filament are you using and which profile are you using? Does the profile match your nozzle size?

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I like you and like many others are having a lot of trouble with this printer. I was just thinking, they have solled a couple of miljons of them and until now they could not resolve these issues!!!?
At least they could put some gadget together that could help us all, and Most of us are happy for paying the money for allready I have paid over 1600 us dollars for my Bambu, but I have not heard anything any help for us the customers!!!?