Disclaimer: I’m relatively new to my TAZ so I may not use the correct terminology. The printer and all its parts are directly purchased from Lulzbot as is the PLA filament.
I am experiencing a frustrating failure when printing with PLA where after successfully leveling the bed, manually extruding to check for consistent flow, and starting a print that appears to have excellent bed adhesion and overall print quality where the print suddenly fails after several hours. I’ve had this happen to me a couple times.
The hobbed gear appears to lose traction on the filament and the extrusion volume drops and becomes whispy. The extruded filament suddenly stops adhering to the layer below. The transition from good quality output to failure happens very suddenly (in the example below it happened within the time to print one layer). After the failure when I peel back the idler bearing the hobbed gear teeth are full of PLA chips and the filament itself is eaten into.
I’ve attached some images to illustrate the failure where I was trying to print a dual-fan duct as suggested by Smiley in this forum post (https://forum.lulzbot.com/t/filament-stripping-issues/662/1) to reduce any possible PLA expansion issues that might be jamming the extruder.
My first guess is that my idler tension is not set correctly but given that I have been able to print good quality output for several hours before the sudden failure occurs I question that impulse. Maybe I’m not clear on how to correctly set the idler tension (for example Piercet suggest that there should be 9mm between the washers on the sprint (https://forum.lulzbot.com/t/extruder-had-one-job/573/2)?
Can anyone help suggest what might be the issue or better yet a solution?
Thanks in advance.