Rostock Max V2 layer alignment and shifting problem

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c0nt4ctu5
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Rostock Max V2 layer alignment and shifting problem

Post by c0nt4ctu5 »

Fairly suddenly I've started to have layer problems with my RoMax V2. Here are some of the successful prints from the first week I had the printer where things worked great and I had (minimal) problems. The whitish cube and the orange peg board were printed out really well and had no problems, as did pretty much all other prints I had.
good_cube1.jpg
good_cube2.jpg
peg_board.jpg
However, recently all my prints are coming out like this one: Some prints will start out fine but after a few layers will start to slant and then eventually the layers get all janky and messed up.
unnamed.jpg
x_axis.jpg
y_axis_L.jpg
I've only had the printer for about 3 weeks and this is my first printer. My original fear was that I had damaged the nozzle on my first multi part print because it sounded like it was dragging across the previous layer as it moved across the print surface (which seemed weird as I do have z lift of 0.3 mm enabled). When that print finished I noticed that the walls of the print weren't straight and seemed to wiggle up the side. I figured it had to do with cooling as it was one of my first few prints with ABS and the piece that was most messed up was in the front and would have been most effected by the draft caused by my AC. But now all my prints since then look like the black cube and have layers that are shifted all around. NOTE: looking at the print from the front of the printer, the layers shift to the right along the X axis and back on the Y axis, BUT its not at the same rate. Some layers are nice and straight for the Y axis up to a certain point (about 1cm off the print surface) before beginning to shift. The X axis shift is very mild until it gets to the same point (about 1cm) then it gets drastic and shifts around. The Z axis seems to be unaffected and is the same as it was when it printed properly.

I've calibrated my z height as per the SeeMeCNC manual, re-ran the PID autotune for hot end and bed, switched to a different outlet (thinking it might have been an issue with pull on the power), and tried 3 different filaments (ABS and 2 colors of PLA that I have).

I can't seem to fix the issue, anyone ever run into this before or have any suggestions? I think my next step is to disconnect the cheapskates and check the belts for any missing teeth or worn out areas and also recheck how square the towers are to the heated bed.

Extruder temp: 210 (with the PLA) and 228 (with ABS)
Bed Temp: 70
layer height: 0.2mm (first layer 0.3mm)
Layer fan: tried with it on and off
print speed: tried at 30, 40, and 50 mm/s
Infill: GRID @ 0.25 fill density (starting angle of 45)
Z lift: 0.3 mm @ 110 mm/s
length on move: 6.5 mm
Using MatterControl and printing via USB
Polygonhell
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Re: Rostock Max V2 layer alignment and shifting problem

Post by Polygonhell »

The fact the side is wiggly implies you have a mechanical issue, check the bets/pulleys/cheapskates.
The top part being printed at an angle implies either you lost steps on one axis, or something slipped on the axis, which to me points at either a lose pulley or a damaged or very loose belt, so I'd start there.
c0nt4ctu5
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Re: Rostock Max V2 layer alignment and shifting problem

Post by c0nt4ctu5 »

Got home too late to pull it apart, tomorrow I'll check the belt and pulley tension. I'm thinking since it seems to be leaning away from the "x" tower that something has to be wrong there.
Mac The Knife
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Re: Rostock Max V2 layer alignment and shifting problem

Post by Mac The Knife »

And don't forget to check the set screws for the drive pulleys.
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c0nt4ctu5
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Re: Rostock Max V2 layer alignment and shifting problem

Post by c0nt4ctu5 »

I removed the "X" tower belt completely and inspected it: no damage, looks brand new still. Remembering how much of a pain it is to disassemble and reassemble the belts I then proceeded to simply retighten all the belts and try a test print. I tried the Make: 2015 3d Printer test file for Z resonance because its a simply tower and should show the wobble easily. Well, to my surprise after about an inch or so it straightened out and printed the top half pretty straight:
unnamed (2).jpg
unnamed (1).jpg
So some of the more drastic leaning seems to have gone away but I guess the next step is to break the thing down and check the other 2 belts. Weird that it would straighten back out and finish correctly.
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Re: Rostock Max V2 layer alignment and shifting problem

Post by geneb »

Check the gear on the stepper motors. One may be slipping a bit.

g.
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c0nt4ctu5
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Re: Rostock Max V2 layer alignment and shifting problem

Post by c0nt4ctu5 »

SUCCESS!

So finally got some time to work on the RoMax over the weekend and I finally found the problem. After taking the belts off of all the skates I went to check how tight each skate was to see if the bearing/wheels needed to be tightened or loosened. On the "Z" tower there was a noticeable "bump" when moving it along its track. I also noticed that this bump was pretty much around the area where the skate would be when printing low to the platform. When I moved it the full distance along the tower i noticed i felt it multiple times and then it clicked: there must be something on the bearing/wheel. So i ran a moist cloth along the wheel and readjusted it to the point where it was tight to the tower and allowed no wobble and i couldn't feel the bump. After reassembling the printer and warming it up a printed out a few items and to my elation they printed out right!

Make 2015 3d Printer shootout Z resonance tower:
Correct Tower.jpg
CuteOcto from Thingiverse:
Correct CuteOcto.jpg
Now I can get back to dealing with my slight over-extrusion problem.
Thanks everyone for the suggestions and the help!
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