Print doesn't match preview

Bambu Lab A1 Series Troubleshooting
1

I’ve been printing pieces for a cosplay costume for my son. They are too big for the A1 Mini so I’ve been splitting them up and it’s been working OK. But I’ve just hit a strange problem where the printer isn’t printing what the Bambu Studio preview shows.

I thought it may have just been some corruption when sending the instructions to the printer, but when I retried it started printing the exact same, wrong, thing.

Anyone have any ideas on what could cause it and how to avoid it?

  • A1 Mini
  • Latest Firmware
  • Latest Bambu Studio
  • Printing via Cloud (WAN, right?)
  • Reused Print Profile / entire process that worked for others
  • Bambu Matte PLA
  • 0.6mm nozzle
  • Plate 1 in the attached 3mf file

PXL_20250325_032759796
PXL_20250325_0327597961920×1440 219 KB

Screenshot 2025-03-24 at 9.28.49 PM
Screenshot 2025-03-24 at 9.28.49 PM1920×1313 92.1 KB

Right Shoulder.3mf (4.1 MB)

2

Well, it was the latest Bambu Studio when I posted - I just got prompted to install a new 2.0 version so I’ll give that a try and see if it still does it.

Update: I re-divided the piece into printable parts using Bambu Studio 2.0 and the first part started printing as expected (like the previous ones). So touch-wood, it was just some weird one-off anomaly.

3

I discovered that if I re-orient some of the pieces it then reports “non manifold edges” so I wonder if that (ambiguous geometry) is what caused the weird print? Strange that it doesn’t warn when doing the initial cut, but I’ll look out for it in future. Apparently I can’t fix it in Bambu Studio on a Mac … which sucks.

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