E3D V6 under extrusion

Discussion in 'E3D-v6 and Lite6' started by Zak062, Feb 14, 2019.

  1. Zak062

    Zak062 Member

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    Printer: Alunar M505 (Anet A8 clone)
    Slicer: Cura
    Firmware: Marlin
    Nozzle: .4
    Filament: 1.75 PLA

    Slicer settings
    Layer height: .2
    Print temp hatchbox: 200
    Print temp inland: 220 (it recommends 215-230)
    Speed: 40 m/s (I've knocked this down to 30 before)
    Retraction: 0-2 mm


    Exact E3d V6 i bought
    https://www.amazon.com/gp/product/B00NAK9L6Q/ref=oh_aui_search_asin_title?ie=UTF8&psc=1

    Settings and printer album
    https://i.imgur.com/AxOoFwD.jpg (overview)
    https://i.imgur.com/ueURrD7.jpg (overview)
    https://i.imgur.com/LMgQo9G.jpg (new nozzle)
    https://i.imgur.com/vIuleHF.jpg (hotend)
    https://i.imgur.com/ehX35nV.jpg (hotend)
    https://i.imgur.com/3wZGWJg.jpg (hotend w/out fan)
    https://i.imgur.com/vrBE1b4.jpg (extruder)
    https://i.imgur.com/VqX0aoU.jpg (extruder)
    https://i.imgur.com/yKldZhk.jpg (extruder)
    https://i.imgur.com/EYrKdaq.jpg (cold pull)
    https://i.imgur.com/hluMEcS.png (settings)
    https://i.imgur.com/6WBwAuW.png (settings)


    Some of the prints
    https://i.imgur.com/EKR6JY7.jpg (most recent this morning)
    https://i.imgur.com/cNFgsmk.jpg
    https://i.imgur.com/QJUpTuG.jpg
    https://i.imgur.com/bfzsvll.jpg
    https://i.imgur.com/jfgvBZE.jpg
    https://i.imgur.com/cI098Z6.jpg
    https://i.imgur.com/XcmjN2e.jpg
    https://i.imgur.com/guYAoxG.jpg
    https://i.imgur.com/JDH7fdR.jpg
    https://i.imgur.com/c45CWhu.jpg
    https://i.imgur.com/k2mgSB4.jpg


    I purchased a genuine E3D V6 bowden about 8 months ago and I've been having under extrusion issues ever since. It's a bit random and I'm at my wits end. Sometimes it will print just fine, other times i can't even get the first layer down. Sometimes it will completely clog, other times it will only partially clog for a single layer. There is no consistency.

    The printer is fairly modified, bigger PSU, pi running octoprint, glass bed, mosfet, 40 mm extruder fan, auto bed leveling, remote extruder. I just swapped out the nozzle this morning hoping that was it but I still had under extrusion. I did a few cold pulls last night that didn't appear to have any debris.

    Things I've tried.
    Upgrade extruder fan to 40 mm.
    Worm gear for extruder.
    2 different brand of filament, 3 different rolls.
    Baked my PLA.
    Measured extruder steps at least 4 times, it's spot on at 50 mm.

    ANY suggestions, no matter how big or small, are welcome. I've been battling this for months now and I'm almost ready to just get a different hotend.


    EDIT: I don't know how to have my imgur albums not show up as media. I'm trying to link them but it keeps converting it to a media.

    EDIT2: i've resorted to linking the individual pictures.
     
    #1 Zak062, Feb 14, 2019
    Last edited: Feb 14, 2019
  2. jfb

    jfb Well-Known Member

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    I can only think of four possibilities:
    • Insufficient power or slipping from the extruder
    • Incorrect hotend assembly
    • Too tight a bend in the bowden, resulting in the filament being squeezed
    • Faulty machining in the hotend and/or nozzle (out of spec, rough interior etc)
    I'm assuming that you've already checked for any blockages and done a cold pull etc, so the above is all I can think of to check.

    For what it's worth, I've been using V6s for a few years now on a couple of different printers, and the only issues I've had have been caused by me. I suspect in your case, you may have an out of spec hotend, which, while I would consider it unusual for a genuine part, is clearly not impossible.
     
  3. Zak062

    Zak062 Member

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    TLDR at bottom

    Thank you for the informative, concise reply. I suspect you may be right. I've heard nothing but good things when it comes to E3D so i suspect I've gone and made some stupid little mistake some where along the line.

    I think we can rule out the bowden bend from my photos. I used the official guide when i assembled the hotend. I also looked at alternative guides to see if there are any differences and I didn't see any. I also don't believe I have a faulty hotend/nozzle. I already replaced the nozzle once and I inspected the hotend parts prior to assembly. I'm one of those that likes to lay everything out and double check all the pieces. (you should see me assemble ikea furniture.) That pretty much leaves the extruder.

    This morning i re-did my firmware from scratch to rule it out. In the process of measuring steps per mm, I noticed that the worm gear slipped a little too easily for my liking. I don't know the exact tolerances but I think it should hurt me if I press the filament into my hand (it was not). Kind of a crude way to measure it but I think you get the point. I swapped the worm gear assemble for the stock spur gear that game with the printer. I'm about half way through printing a test cube at the moment and it's flawless. Somewhere down the line I upgraded to a worm gear and it seems to not be a very quality one. I'm not poping the champagne yet but I'm very hopeful. I will update after a few good prints.

    I appreciate you helping me focusing my efforts jfb.

    TLDR: Worm gear bad, spur gear best
     
  4. jfb

    jfb Well-Known Member

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    Certainly sounds like a likely cause of the problem. Good luck!
     
  5. Zak062

    Zak062 Member

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    I think it's safe to say it was my extruder gear now. Several prints later, including a 11 hour print, and we're all good. Benchy below for reference. Thanks again jfb!

    https://i.imgur.com/QLb63Et.jpg
    https://i.imgur.com/vUPpGw9.jpg
     
  6. jfb

    jfb Well-Known Member

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    Looking good. Glad you got it sorted, and thanks for the update :)
     

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