Under Extrusion leads to Extrusion Motor Overload

Hey guys!
I’ve been running into an issue on a particular model that causes under extrusion leading to an Extrusion Motor Overloaded error. The problem seems to start with a bit of stringing that becomes an error shortly after.

I don’t believe its a nozzle clog, or at least not a complete one. I can usually resume the print once or twice before the under extrusion weakens the print. I’d say its the model, but the problem pops up at random heights. Its mostly in the middle, but also happened under 50 layers, and once barely 70 from the end.

Model is the suppressor for Halo ODST SMG prop printed vertically on a PEI Smooth plate using PLA Basic Black with Support for PLA on the external spool.

Did some reading around here, so I’ve cleaned and reassembled the tool head not finding any debris, tried printing with the door open to no avail, using different colors, and I’ve also printed different models with no issue at all, including an 18hr dragon with 5 colors.
AMS doesnt seem to be binding up at all either.

Any ideas what causes this and what would the solution be?

Pictures and 3mf attached.





Suppressor tk3.3mf (388.8 KB)

You’re not sharing the 3mf with your filament settings, unless you’re trying to print pla and abs together:

Fixed! Must’ve saved over from another print.
Settings are now what they should be.

If you’ve made any changes in the latest version of Bambu Lab Studio, be aware that there’s a nasty bug that can revert your settings back to older values. I discovered this when a 14-hour ASA Aero print failed — it ran much faster than it should have because all my speed settings had reset themselves.

It seems to happen when you change a default value to a custom one. In that case, the entire .json file for your process and/or filament profile may revert to its “default” state again.

I posted a small workaround here:

If you want to stay safe in the meantime, disable cloud sync — it’s currently broken and doesn’t behave as intended.

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