Failure to Print
Two part statement (a question, and a thought process)
It occurs to me that I have a frankly unacceptable level of failures. I Hope to correct this when filament from a completely different vendor arrives sometime this week. So, the question:
****How long have you been printing? What percentage of those prints are failures?
****What mechanisims could be put in place to reduce those failures?
I see the effort placed in auto-bed levelling, so there’s clearly a large amount of brainpower involved at the bleeding edges of the hobby (as presumably a printer in calibration will stay in calibration.)
It seems to be there needs to be a method to determine when filament stops flowing. Whether this is an optical process whereby nonintrusive marks are placed on the filament, then read after the extruder (Bowden), or something that monitors the power sent to the extruder over time (presumably, a non-flowing extruder’s power requirements are different than one operating properly).
I could see a two part camera based failsafe that ‘looks for daylight’ under the extruder then reacts if it sees something it shouldn’t…but then there also needs to be a recovery process that allows the printer to step back through the g-code and pick up where it leaves off.
I’ve had some small successes in recovering from failed prints, that process consists of: unblocking the nozzle, manuallg jog the nozzle down to the Z height of the failure, and manually searching for z=, reinitializing the variables, then kicking the process back off.
Failure occurs when the system looses calibration of the effector location (due to me taking too long), or thermal events prevent the filament from sticking to the cold part (but that was ABS, on a printer that really isn’t configured for ABS)
We’re working with some serisouly small tolerances, and there’s been a LOT of people looking at printing…is there no solution because it’s not an easy problem to solve, or am I standing on an edge that hasn’t actively been looked at? (I can’t believe the big players haven’t looked into it…especially if pre-marked filament would mean patents, proprietary cartridges and the marketing for ‘fail-proof prints’)