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My X1C (~600 hrs) starting having issues with ‘fail to extract’ and ‘fail to load’ errors, that were infrequent at first but now are inevitable with most any print requiring a filament change. It took awhile but I realized that the real issue was thin filament debris being left behind in the filament sensor which led to the above error messages. Debris is also building up inside the extruder but that doesn’t cause immediate stoppages. Some internet searches said that I should replace the extruder gears and filament cutter, which I did but the issues began again right away regardless. I’m kind of a newbie and don’t know what to try next. Please help!
Kind of a longshot but there was a post here recently on 3rd party dual color filaments separating into the component colors physically as the strands came apart in the extruder feed.
What kind of filament are you using? It’s odd to see those somewhat intact bits of strands up in the feeder.
Green and clear PETG? Or a green and a 3rd party clear PLA?
In the latter case, clear, untinted PLA can be temperamental. I prefer to use PETG (with all that entails) when needing transparency.
OK. I am afraid that I am not familiar with the support filament as I either just use PLA for PETG (and vice versa) or BVOH.
But I have had my fair share of troubles due to brittle filaments (like old clear PLA!) or soft filaments (silly experiment with TPU, moist BVOH,… similar error image!).
My X1 has well over 5000h with its 1st extruder (mainly PLA, PETG but also a lot of Woodfill, various CF loaded materials PETG, PA6,…).
So I’d recommend to
clean the extruder really well (making sure to get into the ridges of the extruder gear),
checking the paths to the nozzle and the filament sensor for residue and blockages,
doing a number of hex key cold pulls on the nozzle,
cutting the first 30cm of each roll of filament (check for grind marks),
drying them thoroughly and
=> only then trying again
& 