Stop messing with the software and look at the machine. Sudden changes are far more likely to be a worn or loose part. Go over your machine… Look at it like you want to find something wrong. Print a 10x10x10 mm cube. Mark it for orientation to your machine axis. Measure it with calipers. The out of speck side will point to the axis to inspect.
@Whosa_whatsis Yeah, it is not aligning with the layers. No, we are not using Auto leveling. But, as per Rob Povey, lines are matching with lead screw threads.
But you are printing in vase mode right? So the error would be in a spiral like on the picture. This would not be possible if it is hardware problem. So I am pretty sure it is a software problem as I described earlier.
Do you have any pictures of your extruder? That’s a weird pattern, and looks like the nozzle is starved. Did you clean your feed gear? Any strange tension on the spool?
If you’re not using auto-leveling and the lines are not along layers, it doesn’t matter if it matches the screw threads. That must be a coincidence, because screw pitch errors can’t occur out of the plane of the layer without autoleveling. I suppose vase mode interacting with stepper error could also cause this, but then it wouldn’t happen on non-vase-mode prints.
@Whosa_whatsis thanks for confirming my suspicion there. I hadn’t replied yet because I was trying to figure out how in the hell those layer lines A) matched the screw pitch, and B) crossed the layer lines at such an incredible angle. I didn’t think mechanically that could happen due to screw thread issues. Could this be something like a bad ball bearing in one of the races allowing the X axis to tilt at different heights? That could account for the Z shift at a radical angle maybe?
I can’t think of any way to get an artifact to occur that regularly without stepper resolution being at fault. Crossing layer lines means that some interaction between the z axis (or, much less likely, the e axis) and one or both of the x and y axes is required.
@Whosa_whatsis@ThantiK@Francis_Lee .
Thanks for your support.
I changed stepper drivers, stepper couplers. Replaced left side lead screw to right side and vice versa.
No results. Changed the Y axis pulley. Realoaded the firmware. Removed and tighten the extruder again.
With these all changes, the result was same.
Then all of a suddent print started skipping suddenly and frequently.
Then we found that the Y axis motor became faulty. It stops rotating frequently.
When we removed and tried to rotate manually, it was not rotating freely.
We replaced the motor and checked. Almost the issue has gone. So, final decision is that motor was faulty.
@Tech_World thank you so much for your reply and letting us know what it was; that way we can learn to spot this kind of thing as well. SUPER odd that it was the Y axis motor. I don’t understand mechanically how it could have created a spiral, because it would have been in the same spot relative to where the print was happening - so I’m still kind of confused as to how it was spiraling so regularly.