Diagnosing Replicator 2 Printing Problems

[Blaine Bohun]

I'm having two issues with my Replicator 2 Printer at the moment. I'm new to the printer so I'm still learning how to diagnose problems.

1st Problem: As I print tall objects it appears that I'm missing layers and it affects the structural integrity of my prints.

2nd Problem: I'm trying to print a Raspberry Pi case and the first layer doesn't print very well and it looks like no plastic is coming out of the extruder as it lays down each line.

Thank you for the help, I'm hoping to learn how to diagnose these problems so I can fix them without having to bother you guys!

[Blaine Bohun]

Still having these issues with Orange PLA too.

[Eighty]

Blaine,
Those pictures represent two separate issues.

The first layer problem can be caused by many factors. Despite Damian's EXPERT opinion, it looks like you're getting pretty decent flow. I recommend trying two things: first, make sure your bed is good and clean (wipe it down with rubbing alcohol). Fingerprints will prevent good adhesion. Second, slow down your first layer considerably. The first layer is the key to a successful print, and the slower the better. Too fast will cause dragging of the extruded noodle, followed by the little gum balls in the pic.

It's hard to tell by the picture what the real issue is on the upper layers. If that was supposed to be a uniform side surface, then I'd hazard to guess that you're extruding too much plastic. That's usually evident with bulging or streaky outer shells. As the back pressure builds, your extruder will jam up until the back pressure bleeds off (while air printing). I didn't catch what settings you're using, but I'll assume its a standard Makerware profile. For PLA, make two changes: revise the FeedstockMultiplier to 0.97, and enter the ACTUAL filament diameter into the profile (as measured with calipers). That will get you a much better start on everything. If you're still having problems, post some new pics so we can look for other clues.

[Steve]

Blaine:

+1 for Eighty's comments, good advice.

Also, make sure your build plate is not warped (that has been an issue). Then level using the standard instructions. Then level by printing a single layer part, a square or circle. and adjusting the leveling screws until the first layer is even and clearly squished onto the build plate. If you do not get a good first layer there is not point in continuing the print.

The problem may also be with the slicer profiles you are using, or the part design itself not being flat on the bottom, but it seems that many issues like this for new printers go back to inaccurate leveling and non-flat build plates. 

Steve

[David Celento]

Print the stretchlet on the SD card. If you get gaps around the entire ring you have A) thermocouple problems, and/or B) hot end wire problems

(I had both.... Took 3 months to diagnose and solve)

Turn machine on and off before each print to reset motherboard.

[Blaine Bohun]

Thank you guys! Since I've posted this, I've installed ReplicatorG and I'm using Wingcommander's 100 micron profile from Thingiverse and I've adjusted my delgrin plunger. I'm seeing much better prints but I do still occasionally get that first layer problem. I've been using rubbing alcohol but I think the culprit is that my acrylic plate is a tad bit warped. Thanks for all the help, you guys really know your stuff. I have a lot more confidence in this printer.

On Thursday, April 4, 2013 8:55:23 AM UTC-6, Blaine Bohun wrote:

[Bryon Miller]

You should print wingcommanders extruder upgrade, it is much better than the delrin plunger.  In fact, I'd either order it from eBay with the parts or try to get one for free from MBI because those will be printed in ABS and can take more heat.  There was an aluminum build on a group buy here also, I'd like to get in on the next one, I think I missed the last one.

[Kerry Chin]

Definitely you need the upgrade. The MB one works well too. The delrin plunger is a bad joke. Mine wore a nice groove after about 20 hrs of printing.

[David Celento]

Good advice offered above.

Here's a guide for new users that I put together. http://www.thingiverse.com/thing:71575

Perhaps this will help cover some of the variables Eighty is mentioning. The Troubleshooting section may be of particular interest.

~Dave