Turned out to be a Z-offset in my slicer I dismissed because I needed it before.
All is working as it should now.
Thank you for your help, and the debugging assist!
M350 X16 Y16 Z16 E16 I1 ; configure microstepping with interpolation
M92 X80.00 Y80.00 Z80.00 E403.00 ; set steps per mm'
Adjusted back to these settings.
printing one now... this is going to be funny.
@crpalmer I have reduce the extruder steps all the way down to 160... still happening...
Starting to rule out overextrusion.
adding current config.g
; Configuration file for Duet WiFi (firmware version 2.03) ; executed by the firmware on start-up ; ; generated by RepRapFirmware Configuration Tool v3.3.4 on Sun Oct 10 2021 10:43:02 GMT-0400 (Eastern Daylight Time) ; General preferences G90 ; send absolute coordinates... M83 ; ...but relative extruder moves M550 P"HOWEE" ; set printer name M555 P2 M665 R157 L397.107 B175 H525 ; Set delta radius, diagonal rod length, printable radius and homed height M666 X0.15 Y0.08 Z0.07 ; put your endstop adjustments here, or let auto calibration find them ; Network M552 S1 ; enable network M586 P0 S1 ; enable HTTP M586 P1 S0 ; disable FTP M586 P2 S0 ; disable Telnet ; Drives M569 P0 S1 ; physical drive 0 goes forwards M569 P1 S1 ; physical drive 1 goes forwards M569 P2 S1 ; physical drive 2 goes forwards M569 P3 S1 ; physical drive 3 goes forwards M584 X0 Y1 Z2 E3 ; set drive mapping M350 X32 Y32 Z32 E32 I1 ; configure microstepping with interpolation M92 X160 Y160 Z160 E810 ; set steps per mm M566 X1500.00 Y1500.00 Z1500.00 E1500.00 ; set maximum instantaneous speed changes (mm/min) M203 X39960 Y39960 Z39960 E3000.00 ; set maximum speeds (mm/min) M201 X1000.00 Y1000.00 Z1000.00 E1500.00 ; set accelerations (mm/s^2) M906 X1100 Y1100 Z1100 E880 I30 ; set motor currents (mA) and motor idle factor in per cent M84 S30 ; Set idle timeout ; Axis Limits M208 Z0 S1 ; set minimum Z ; Endstops M574 X2 Y2 Z2 S1 ; set active high endstops ; Z-Probe M307 H3 A-1 C-1 D-1 ; disable heater on PWM channel for BLTouch M558 P9 H5 F120 T6000 ; set Z probe type to bltouch and the dive height + speeds M558 H30 ;*** Remove this line after delta calibration has been done and new delta parameters have been saved G31 P500 X0 Y20 Z4.4 ; set Z probe trigger value, offset and trigger height M557 R150 S45 ; define mesh grid ; Heaters M305 P0 T100000 B4138 R4700 ; set thermistor + ADC parameters for heater 0 M143 H0 S100 ; set temperature limit for heater 0 to 100C M305 P1 T100000 B4138 R4700 ; set thermistor + ADC parameters for heater 1 M143 H1 S280 ; set temperature limit for heater 1 to 280C ; 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 H1 T45 ; set fan 1 value, PWM signal inversion and frequency. Thermostatic control is turned on ; Tools M563 P0 D0 H1 F0 ; 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 ; Custom settings are not defined ; Miscellaneous M911 S10 R11 P"M913 X0 Y0 G91 M83 G1 Z3 E-5 F1000" ; set voltage thresholds and actions to run on power loss
@t3p3tony like the Z steps aren't moving appropriately. As soon as the second layer starts, you can hear the hotend dragging across the print, eventually either breaking the extruded material free of the bed, or creating a very deformed print. This still feels like either an extrusion issue, or a z steps being off issue.
but first problem is definitely fixed.