We purchased a Workhorse at my job for help with prototyping about 9 months ago. Generally, we do pretty straightforward, extruded 2d shapes, nothing crazy. Lately we’ve been expanding what we do with the printer and some of the shape have been giving me trouble. When printing a profile with inset or protruding features, the layers become misaligned on the part on the surfaces only adjacent to said feature (see attached pictures of a Benchy representing my best shot right now). I’ve gone pretty far down the rabbit hole trying to solve this on my own, but have come to a dead end and now need fresh ideas for a solution. Here’s a laundry list of things I’ve tried:
- Ensured bed is level
- Ensured all axes are tight with no play
- Calibrated E-Steps
- Calibrated K-factor
- Tuned PID
- Played with retraction settings
- Slowed the print speed
- Reduced layer height
Not sure what to do next to fix this. Anyone else have this problem? When I search for others having layer misalignment issues, I have not found this particular variation of it. Hoping someone here can help out!
On the plus side, all the additional tuning time here has helped improve parts that don’t have this type of feature, haha!