Can anyone help with these print quality issues



  • Hi all,

    I've got a Wanhao i3 plus cartesian printer with direct drive extruder (Flexion HT) on the x axis. All motors are around 1A 1.8 degree steppers with the exception of the extruder which is 1.68A and 0.9 degrees.

    Would someone mind reviewing my config.g file below and point out any values that stand out as being a bit extreme, especially around the drive section. The main issues I'm trying to resolve are inconsistent extrusion (frequent under extrusion), oozing & zitting, ghosting on both horizontal axes & small layer shifts up the z axis.
    I normally print about 50 mm/s and slice with Simplify 3D.

    EDIT (added pictures):
    This 20mm clear PETG vase mode cube shows the issues best.
    0_1527970753330_20180602_194942.jpg

    I ran some tests to check how microstepping improved things. I ran the same cube print but at 6mm/s in PLA+ (215 degrees) at different microstepping settings.

    x16 with interpolation (left) : x16 without interpolation (right)
    0_1527970998049_20180602_194507.jpg

    x32 (left) : x64 (right)
    0_1527971125246_20180602_194537.jpg

    x128 (left) : x256 (right)
    0_1527971112594_20180602_194602.jpg

    I then ran the same print at 60mm/s with x16 (interpolation) and x256.

    x16 with interpolation (left) : x256 (right)
    0_1527971228312_20180602_194739.jpg

    I then ran the same print at 30mm/s at x16 (interpolation) and compared with the 6mm/s and 60mm/s x16 (interpolation) prints.

    6mm/s (left) : 30mm/s (middle) : 60mm/s (right)
    0_1527971388385_20180602_194912.jpg

    I'd be interested to hear people's thoughts but it looks to me like the microstepping settings make very little difference (at least at slow speeds).
    There is an improvement in the flat face at 60mm/s but the edges look terrible. COuld this be due to jerk settings?
    There is a further improvement when printing at a middle speed of 30mm/s but still some issues on the edges (note the lifted top corners).

    I was always under the impression that printing slower should produce better quality. I was also under the impression that different microsotepping settings should have some effect on print quality.

    After months of research and trying to fix these problems I'm basically at my wits end! So any help would be appreciated. With these in mind can anyone help me solve these problems?

    config.g

    ; Configuration file for Duet WiFi (firmware version 1.20 or newer)
    ; executed by the firmware on start-up
    ;
    ; generated by RepRapFirmware Configuration Tool on Wed Mar 07 2018 10:07:16 GMT+0000 (GMT)
    
    ; General preferences
    G90                                                                            ; Send absolute coordinates...
    M83                                                                            ; ...but relative extruder moves
    M555 P1                                                                        ; Set firmware compatibility to look like RepRapFirmare
    
    ; Network
    M550 Pxxxxxxxxxxxxx                                                           ; Set machine name
    M551 Pxxxxxxxxxxxxx                                                              ; Set password
    M552 S1                                                                        ; Enable network
    M586 P0 S1                                                                     ; Enable HTTP
    M586 P1 S0                                                                     ; Disable FTP
    M586 P2 S0                                                                     ; Disable Telnet
    
    ; Drives
    M569 P0 S0                                                                     ; Drive 0 goes backwards
    M569 P1 S1                                                                     ; Drive 1 goes forwards
    M569 P2 S1                                                                     ; Drive 2 goes forwards
    M569 P3 S1                                                                     ; Drive 3 goes forwards
    M350 X16 Y16 Z16 E16 I1                                                        ; Configure microstepping with interpolation
    M92 X80 Y80 Z400 E199.99                                                       ; Set steps per mm
    M566 X480 Y480 Z12 E120                                                        ; Set maximum instantaneous speed changes (mm/min)
    M203 X9000 Y9000 Z600 E3000                                                    ; Set maximum speeds (mm/min)
    M201 X800 Y800 Z100 E5000                                                      ; Set accelerations (mm/s^2)
    M906 X760 Y760 Z760 E1300 I30                                                  ; Set motor currents (mA) and motor idle factor in per cent
    M84 S30                                                                        ; Set idle timeout
    
    ; Axis Limits
    M208 X0 Y0 Z0 S1                                                               ; Set axis minima
    M208 X190 Y200 Z175 S0                                                         ; Set axis maxima
    
    ; Endstops
    M574 X1 Y1 S0                                                                  ; Set active low endstops
    
    ; Z-Probe
    M307 H3 A-1 C-1 D-1 ;
    M558 P9 H5 F160 R0.250 T2000 A3                                                ; Set Z probe type to bl touch and the dive height + speeds
    G31 X41 Y-47 Z1.60 P25                                                         ; Set Z probe trigger value, offset and trigger height
    M557 X18:182 Y18:182 S25                                                       ; Define mesh grid
    
    ; Heaters
    M301 H0 S1.00 P10 I0.1 D200 T0.4 W180 B30                                      ; Use PID on bed heater (may require further tuning)
    M305 P0 T100000 B3988 C0 R4700                                                 ; Set thermistor + ADC parameters for heater 0
    M143 H0 S120                                                                   ; Set temperature limit for heater 0 to 120C
    M305 P1 T100000 B4725 C0 R4700                                                 ; Set thermistor + ADC parameters for heater 1
    M143 H1 S280                                                                   ; Set temperature limit for heater 1 to 280C
    M307 H0 A90.0 C700.0 D10.0 S1.00 V0.0 B1                                       ; PID tuning - set automatically (M303) and moved from config-override.g
    M307 H1 A458.2 C201.5 D3.2 S1.00 V24.0 B0                                      ; PID tuning - set automatically (M303) and moved from config-override.g
    M307 H2 A340.0 C140.0 D5.5 S1.00 V0.0 B0                                       ; PID tuning - set automatically (M303) and moved from config-override.g
    M307 H4 A340.0 C140.0 D5.5 S1.00 V0.0 B0                                       ; PID tuning - set automatically (M303) and moved from config-override.g
    M307 H5 A340.0 C140.0 D5.5 S1.00 V0.0 B0                                       ; PID tuning - set automatically (M303) and moved from config-override.g
    M307 H6 A340.0 C140.0 D5.5 S1.00 V0.0 B0                                       ; PID tuning - set automatically (M303) and moved from config-override.g
    M307 H7 A340.0 C140.0 D5.5 S1.00 V0.0 B0                                       ; PID tuning - set automatically (M303) and moved from config-override.g
    
    ; Fans
    M106 P0 S0 I0 F500 H-1                                                         ; Set fan 0 value, PWM signal inversion and frequency. Thermostatic control is turned off
    M106 P1 S1 I0 F500 H T45                                                       ; Set fan 1 value, PWM signal inversion and frequency. Thermostatic control is turned on
    M106 P2 S1 I0 F500 H T45                                                       ; Set fan 2 value, PWM signal inversion and frequency. Thermostatic control is turned on
    
    ; Tools
    M563 P0 D0 H1                                                                  ; Define tool 0
    G10 P0 X0 Y0 Z0                                                                ; Set tool 0 axis offsets
    G10 P0 R0 S0                                                                   ; Set initial tool 0 active and standby temperatures to 0C
    
    ; Automatic saving after power loss is not enabled
    
    ; Custom settings are not configured
    M572 D0 S0                                                                     ; Disable Pressure Advance
    
    ; Miscellaneous
    T0                                                                             ; Select first tool


  • I've been reading some threads on the forum and have started testing the different microstep modes.

    I've found that x16 with no interpolation and there is a rhythmic gentle bumping coming from both z steppers, pulsing every ~0.31s.

    Anyone care to guess what this is?



  • you mean every 0.3 seconds you zaxis moves up a bit and back down again?



  • @janko There's no visible jumping in the z axis.

    I just mean that if I touch the frame of the machine I can feel a pulse ever 0.3s. I then felt around and found the source to be both z steppers (in parallel). If I touch the z steppers there's a rhythmic pulsing at x16 microstepping with no interpolation. Also there mildly at x32 and negligable from x64 upwards.



  • @drammy in that way 🙂 The pulsing is i presume some vibration-ish you feel right? Or like a small electric flow (do you start dancing funny every 0.3 seconds when you touch it 😜 )



  • @janko Yeah, that's it. It kinda feels the same as gently tapping the tip of your finger against the edge of a table (quickly 😆).
    I can only dance funny! Or so my wife keeps telling me!



  • @drammy some time ago i had some issues here, which i fixed by using x16 with interpolation. The movement is pretty much as smooth as i could wish for.

    As of feeling the motors: tested it here and i can feel something but barely, not a level that i can imagine it would cause any issue.

    For the oozing: i first configured my printer here to print straight lines, then started tuning the instantDV and acceleration. Last steps: in your slicer up travelspeed (helps bigtime against stringing) and start with retraction settings (there are some testfiles for that on thingiverse)



  • @janko Till now, I've been using x16 with interpolation. It was only when doing this testing that I noticed x16 no interpolation causes the pulsing that was quite noticeable on touch.

    Have nearly finished the test prints at each microstepping setting so will show some pics soon of the problems I'm trying to overcome.

    Do you have any values for the things you're talking about - travel speed for example? Mine is set to 150mm/s..



  • I've updated the OP and added some pictures of my test prints.



    1. Id suggest you leave the motors at 1/16th with Interpolation to 256
    2. Have you calibrated the esteps per mm on your extruder motor ?
    3. On the X Y motors ?
    4. You're positive you have the correct esteps setting for your Z leadscrews ?
    5. This looks like extrusion calibration and retraction calibration ...
    6. Bowden or Direct drive extruder ?

    A. Use "matts hub" extrusion calibration guide to make absolutely sure your extruder esteps are accurate, very accurate.

    B. Make sure you have your extrusion multiplier in slicer set right.

    C. Run some retraction test prints - share those pics

    Find one that prints in under 45 mins ... this one scaled to 200% works pretty quick around 45 mins

    link text

    D. Run X Y Z ... 20 mm cubes - share those - with your best retraction and Pressure advance settings. after C above.

    E. <---- this should prolly be before C. ... run a temp tower on this material to find the near lowest possible temp you can print the material. Use that temp for the retraction tests and maybe even 5C less at the very tips of the retraction test model.

    for now maybe run all these tests at 30-40 mms speeds [ 20 mms 1st layers, external perimeters at 50% of main speed setting ]



  • Hey @sputnikoc3d

    Thanks for the msg. In answer to your q's..

    • list item Id suggest you leave the motors at 1/16th with Interpolation to 256
      • Yeah, will do.
    • Have you calibrated the esteps per mm on your extruder motor ?
      • Yeah, I've run e calibrations a few times but happy to go over it again. Thanks for the link, it looks a good article!
    • On the X Y motors ?
      • Yes, I've found they were stepping a little over 100mm on the 100mm length test I ran and had adjusted these.
    • You're positive you have the correct esteps setting for your Z leadscrews ?
      • I believe so, it is a 8mm per revolution lead screw with a 1.8 degree stepper which at 1/16th should equal 400 steps. Have I got that wrong?
    • This looks like extrusion calibration and retraction calibration ... Bowden or Direct drive extruder ?

    I've got some IGUS bearings and some anodised aluminium rods coming soon so I will put them on the printer and then look to run through the steps you've posted.

    I noticed in the config.g the extruder max speed and acceleration looks high compared to the other steppers - is that right?



  • @drammy

    ; Configuration file for Duet WiFi (firmware version 1.21)
    ; executed by the firmware on start-up
    ;
    ; generated by RepRapFirmware Configuration Tool on Wed Jan 31 2018 09:50:41 GMT-0800 (Pacific Standard Time)

    ;---------------------------
    ; General preferences
    ;---------------------------
    M111 S0 ; Debugging off
    G21 ; Work in millimeters
    G90 ; Send absolute coordinates...
    M83 ; ...but relative extruder moves
    M555 P2 ; Set firmware compatibility to look like Marlin
    ;M669 K0 ; Set Kinematics K=0=Cartesian
    M208 X0 Y0 Z0 S1 ; Set axis minima
    M208 X243 Y220 Z215 S0 ; Set axis maxima
    ;M208 X-15 Y-5 Z0 S1 ; [[ BuildTak ]] Set axis minima for the 220 x 220 Buildtak Bed
    ;M208 X215 Y215 Z215 S0 ; [[ BuildTak ]] Set axis maxima for the 220 x 220 Buildtak Bed
    M564 H0 ; Permits ALL Axis movement prior to or without ANY Homing require [ over-rides default of no movement until all homed ]

    ;---------------------------
    ; Endstops
    ;---------------------------
    M574 X1 Y1 S1 ; Set low-end [ min ] endstops || S1 = NC / Active High S0 = NO / Active Low
    M574 Z2 S1 ; Set high-end [ max ] endstops || S1 = NC / Active High S0 = NO / Active Low

    ;---------------------------
    ; Z Probe / BL Touch Smart
    ;---------------------------
    M307 H3 A-1 C-1 D-1 ; *** Heater 3 *** PIN reassignment for 3.3v BL Touch SMART [ BL Touch Specific settings ]
    M558 P9 X0 Y0 Z1 H5 F200 T6000 B1 A5 S0.02 ; Set probe type [P9] | Axis to probe[1=in use / 0=not used ] | [H5]dive height | [F5 ]Probe Speed | T=Travel Spd |A= #attpts | S= deviation
    G31 X-29 Y-9 Z3.525 P25 ; Set X/Y Horiz offset from probe || Set Z probe trigger height || Trigger Sensitivity Value [ P ]
    M557 X0:175 Y25:200 S25 ; Define the bed x/y min max mesh grid probing area for Mesh Bed Leveling
    ;M557 X0:175 Y25:200 S25 ; [[BuildTakSheet ]] Define the bed x/y min max mesh grid probing area for Mesh Bed Leveling

    ;---------------------------
    ; Drives
    ;---------------------------
    M584 X0 Y1 Z2:4 E3 P3 ; Dual Z Motor Mapping
    M671 X0:175 Y100:100 S2 ; Z Lead Screw Leveling probe Point Mapping
    M569 P0 S0 ; Drive 0 goes reverse [ X Axis ] [ S0 = Rev / S1 = FWD ]
    M569 P1 S0 ; Drive 1 goes reverse [ Y Axis ]
    M569 P2 S0 ; Drive 2 goes reverse [ Z Axis - LT ]
    M569 P4 S0 ; Drive 4 goes reverse [ Z Axis - RT ]
    M569 P3 S1 ; Drive 3 goes forward [ E0 ]
    M572 D0 S0.06 ; Set Pressure Advance [ need to check Jerk and Accel Settings to properly coincide here ]
    M350 X16 Y16 Z16:16 E16 I1 ; Configure microstepping with interpolation
    M92 X100.30 Y100.250 Z1600:1600 E140.64 ; Set steps per mm
    M566 X900 Y900 Z25:25 E250 ; [ Jerk Settings ] Set maximum instantaneous speed changes (mm/min)
    M201 X500 Y500 Z280:280 E250 ; Set accelerations (mm/s^2)
    M203 X6000 Y6000 Z280:280 E1200 ; Set maximum speeds (mm/min)
    M906 X1600 Y1600 Z1600:1600 E1600 I30 ; Set motor currents (mA) and motor idle "power saving" decrease factor as percentage [ I30=30% ]
    M84 S30 ; Set idle timeout



  • I had an issue like this on my old Prusa, I changed settings, calibrated, tuned current, tweaked everything. In the end it was a mechanical problem. One of the horizontal rods that my x carriage rides on had come loose in the mount. I guess what I am trying to say is always look for the obvious first, sometimes we overlook the easy stuff because it looks to easy.



  • Thanks guys!

    I will put the new rods and bearings in and check all the mechanics then recalibrate (for the umpteenth time 🤷) and report back.



  • @drammy

    From what I see its definitely a rigidity / extrusion problem.

    If you want to see significant alteration by changing interpolation you should test a complex gear in vase mode, but after checked rigidity and calibrate your extrusion.



  • @hergonoway Ok, will play with microstepping after then.

    I have had no end of problems with this Flexion extruder. Bought it about 4 months ago and the stock mk8 extruder gave me significantly better results.

    Do you think I should be able to return it?


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