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Wall of shame prints (print failures)

Posted: Fri Feb 24, 2017 1:14 pm
by Jetguy
Here's a print that failed last night. Classic "bird's nest" from multiple XY axis shifts. This was caused by me using higher than normal speeds and over extrusion which caused the nozzle to drag through the previous layers. Completely my fault for pushing my luck with speeds and failing to perform proper calibration. You aren't really in this hobby until you can do this a couple of times and you no longer get mad or upset.

Re: Wall of shame prints (print failures)

Posted: Fri Feb 24, 2017 5:12 pm
by walshlg
my favorite was with ninja: made a big birds nest of a single 400um wide string of soft silky black fiber. I still keep it because it feels so nice.

Re: Wall of shame prints (print failures)

Posted: Fri Feb 24, 2017 6:27 pm
by Jetguy
What I'm hoping to start is people sharing good and bad prints. Not every print is going to be great and yes, we all want to show off success. I'm as guilty as anyone in that regard. But the point is, new folks have no clue what is good or bad, what can happen, what can go wrong. By building both success and failure outcomes you simply learn and it's a part of consumer 3D printing today.

Re: Wall of shame prints (print failures)

Posted: Mon Feb 27, 2017 12:05 am
by walshlg
first-> trying to insert a second color into the wall of a single layer thick vase-> don't orient the wall in the x axis, that is the axis with both nozzles so doing so will cause maximum headstrikes! (note website rotates images)
dual print in xaxis.jpg

Re: Wall of shame prints (print failures)

Posted: Mon Feb 27, 2017 12:07 am
by walshlg
20170226_164532.jpg
No Matter How Many layers you set for bottom layer in extruder, it only prints one if that is how thick you model is!

Re: Wall of shame prints (print failures)

Posted: Tue Feb 28, 2017 2:03 am
by bellatrixzen
This was waiting for me this morning. It is supposed to be two sponge holders for my sink.

Turned out to be a giant, non-absorbant sponge thing.

IMG_20170227_060720552.jpg



I hate ABS

Re: Wall of shame prints (print failures)

Posted: Tue Feb 28, 2017 10:41 am
by myinsta3d
walshlg wrote:
20170226_164532.jpg
No Matter How Many layers you set for bottom layer in extruder, it only prints one if that is how thick you model is!


What material is this?

Re: Wall of shame prints (print failures)

Posted: Tue Feb 28, 2017 1:26 pm
by walshlg
this was petg, makes nice vases with the clear colors that are much tougher than pla, although I still coat with epoxy if going to fill with water

Re: Wall of shame prints (print failures)

Posted: Thu Mar 30, 2017 4:12 pm
by walshlg
What is the worst print failure?? One that makes your machine unuseable! In my experience, most of these have been isolation tube jams caused by the filament breaking off or getting stuck so it sits cooking all night long while not extruding. Eventually, no matter the cooling, it will melt up into the isolation tube requiring a hotend teardown. I have had this usually happen from bad brittle filament but it also happened recently because the filament got stuck. Be careful how you take filament off of the spool, many designs can cause problems:

{SORRY uploading images not working now!}

I built a wall mount to hold large spools but attached the guide tube to the side. Gradually it kept pulling the filament to the side until it bound at the edge of the spool.

Re: Wall of shame prints (print failures)

Posted: Thu Apr 13, 2017 9:11 pm
by redUFO
The worst print fail I had was a couple of months ago that would have resulted in a heck of alot of damage if I hadn't stopped it in time.

I was printing out 1 of the 24 parts that make up a BB-8 inside sphere. Because the shape of these parts they were hands down my most difficult print. They even required some baby sitting and hand filing a certain area that the extruder was hitting.

Anyway, I started the print, then we headed out to go see a movie. When we got home 2 hours later what I saw put me into a bit of a panic. It was clear from look that the print failed while it was laying down a 5 lay raft. The PLA didn't stick to the bed but wrapped itself around the extruder like a ball. I couldn't even see the extruder, just the thing moving in around a ball of white PLA growing larger and larger around it.

So I puckered up a bit, and knew once this cools down it will be pretty much impossible to remove and clean the extruder. So I turned up the heat to max on it. Then I started to poke at the blob of plastic with the cleaning stick that comes with the printer. Eventually I got a big chunk of it off and used a wire brush to clean the printer. If that went on for 8 hours which normally happens while I'm at work or while sleeping. I would have came home to a nightmare.

This alone is why I remind myself to always leave the webcam on so I can monitor it remotely

Re: Wall of shame prints (print failures)

Posted: Fri Apr 14, 2017 3:17 pm
by Billucas
My Wall of Shame Prints... Part 1

Re: Wall of shame prints (print failures)

Posted: Fri Apr 14, 2017 3:18 pm
by Billucas
My Wall of Shame Prints... Part 2

Re: Wall of shame prints (print failures)

Posted: Fri Apr 14, 2017 3:19 pm
by Billucas
My Wall of Shame Prints... Part 3...

Re: Wall of shame prints (print failures)

Posted: Fri Apr 14, 2017 4:21 pm
by walshlg
The bigger the spool, the bigger the problems with friction, Pulling off to side jammed the filament into the edge of the wind

InShot_20170329_213159.jpg

Re: Wall of shame prints (print failures)

Posted: Fri Apr 14, 2017 4:28 pm
by walshlg
Here is one that was actually a success but looked to be a failure: printing 2 color flexible filament you MUST use wipewall:

20161007_155641.jpg


20161007_143134.jpg



20161012_171224.jpg



but it all cleaned up!

Re: Wall of shame prints (print failures)

Posted: Thu Jun 08, 2017 1:07 pm
by walshlg
Found the cause of a 3x midnight failure! Printed PETG 250, bed and chamber about 80C, fan on full.

Right here the model keeps failing - found wrapped around print head pulled off of build plate. THis is a threaded rod spool holder. THe center flat area is the inside of the cylinder printed on 14% fill

PETG curl2.jpg


finally printed with a raft slow and watched what happened. When a line of print starts in mid-air (circled in red) I expected it to sag. NO it curls up just like PLA!! This is what my nozzle kept hitting. Interesting how on the opposite side a loop out and back that is unsupported prints perfectly! So the answer is - even with PETG - unsupported edges will curl up so print with more fill even if you don't need it for strength!
PETG curl1.jpg

Re: Wall of shame prints (print failures)

Posted: Wed Jun 21, 2017 12:48 pm
by woofy
Had this Baby Groot fail about 55 hours into a 65hr print. Sob!

It started with an xy skip. After a while of spewing filament into thin air, the fans stopped and the thermocouple failed. The heater went mad and started smoking. The printed fan cover melted and filament jammed in the throat tube, even with a new Bondtech extruder pushing it.

Its all cleaned out and working again now.
So who wants to take a guess at what failed.

Re: Wall of shame prints (print failures)

Posted: Wed Jun 21, 2017 3:45 pm
by walshlg
woofy wrote:So who wants to take a guess at what failed.


edge curl?

Re: Wall of shame prints (print failures)

Posted: Wed Jun 21, 2017 4:43 pm
by woofy
That possibly caused the xy shift. I haven't insulated the block and I forgot to put a z-hop on.

But the fans stopping and run away over heating?
Despite being separate circuits, they had a common cause. I'd recently installed the Bondtech extruder, and when I re-assembled the head I had too much tension on the 14 way IDC header and it was half way pulled out at an angle, some pins connected some not.

However, I managed to dis-assemble the hot end and got it cleaned up without damage to the throat tube, so kind of happy-ish.