I just purchased a TAZ4, and have printed a few (6 now) items with it in PLA. My first print was Thursday night (three days ago). I’m using the Silver PLA purchased through the Lulzbot website.
Today, I printed a 6cm tall squirrel (my tallest print yet), and a couple times it sounded a little rattly. I let it finish the print, and a couple of the supports (columns) looked a but unravelled, and one side of the model was rather rough. I’m afraid to print now, though, because the extruder gears are covered in a grey plastic powder. The gears are black, so I don’t know where the powder’s coming from. I went through the setup in the manual when I first started printing, and haven’t changed the filament since.
On closer inspection, the plastic flakes may be black. A couple flakes were big enough to see that, while the rest is a rather fine powder. It’s almost as if the gears are disintegrating.
Is this a common thing, and does it have a known resolution?