Heatcreep? Hotend issues?

Hello, I seem to be having a lot of issues with my new Bambu A1 I got last Tuesday. I’ve sent in a ticket to Bambu already, but I figured I’d try here as well. I have also been working with my local hack space to get this solved, as there are others more experienced than me with the insides of a 3D printer to get some help.

Several days ago, I was printing just fine with the Creality Grey PLA filament I have in Orca slicer, and now every single print clogs in the hot end, no matter if I slice it in Bambu studio or Orcaslicer, if I purge the filament at 300 degrees and use the probe, if I cold pull, manually scraping it out, nothing.
I’ve taken the hot end out and made sure the gears and drivers are working - they push filament in with zero issues, and from taking it apart there seems to be nothing wrong with the gears or anything stuck.
I have broken my nozzle probe with how many times I have tried cleaning out the hotend between prints and trying different solutions at different temps, different files, files that have worked before, etc.
I’m going to try cleaning filament next, but I can’t get it until Tuesday. I may try just dunking the whole hot end in acetone or ethyl acetate to get it cleaned, as I’ve seen that as a solution, I have no idea if it’ll work or not. Short of that, I feel I have tried most things to clean the hotend and try to resolve this issue back to normal.

Again, I’ve had successful prints with zero issue, as show here, all done with this filament with the generic settings with no tweaking on Orcaslicer.

And yet, this is what happens for every single print now.



The only other clue I really have is that my cold pulls look like this:


They don’t taper, rather they just…end, all flat like this. I’m unsure what this means.

Please help me if you can - In the end, I know I could probably just purchase a new hotend, but part of me wants to learn why this went wrong/what the issue is so if it happens in the future, I could fix it again.

Thank you!

Have you tried using Bambu Studio with the Generic PLA profile?

When you have purged PLA at 300C, some of the filament might have become burnt inside the hotend, and that could cause a partial clog. It is recommended to perform a few cold pulls to confirm the inside of the hotend is clean and free from any debris that might interfere with the filament flow.

In one of your images shared, it looks like the front cover of the print head is removed. Please try to install the cover on its correct position before trying again as the cover might help better direct the airflow through the hotend heatsink fins.

Yes, these were all done with the Generic PLA profile in both softwares, and the Benchys shown are done with that profile as well, and I have put the cover on as well - same result.

I have a 0.2mm nozzle that I am currently printing another Benchy with - Bambu Studio, default 0.2mm profile, and it is going perfectly well with no issues, so it’s certainly not an extruder or gears issue, but a nozzle issue.