Fill Issues (Page 3 of 4)

I am assuming that is supposed to be completely infilled. The lines look good, straight and even. The only thing I see looks like you have made your overlap 0%, normally it needs to be about 15% so there is some overlap of layers. Otherwise, my only suggestion would be a higher infill %. Sometimes, if you are running a low infill (<20%) even solid surfaces can have skips and spaces.

If you're on the experimental branch of Slic3r (currently 1.2.6), it is under Advanced where the extrusion widths are. If you're on version 1.1.7 (latest stable), this option isn't adjustable. If that's your first layer I have to wonder if you just aren't printing close enough to the bed--I would get results like that until I got the nozzle distance at that "sweet spot".

3  questions...
1. What is the extrusion width set at for first layer?
2. What is the measurement of the cube on the x axis? (actual .vs model)
3. What is the measurement of the cube on the y axis? (actual .vs model)

No need to apologize we've all had those days

Looking good!!! single perimeter is difficult so use at least 2.  If the whole thing becomes perimeters (like your first letters) that's when you end up with holes.  As far as the other nozzle goes there are a couple of things you could do.  I would just turn that one off right after the print starts and see if you get a cold extrusion error.  If not and the other extruder continues to work than manually just turn it back on when you want.  I don't know for sure if that will work as I fully suspect the cold extrusion error.  The other thing you can do is turn the temp down on that nozzle to just above that cold extrusion limit.  Then turn it up when ready.  Something like that could be patched into the g-code to happen automatically.

Thanks again, we wouldn't have a useable printer without everyones help. You've been especially helpful and patient with our problems and with my amateur skills.

Unrelated question, for the print quality, I understood when you posted instead of using .3 to use .2963 etc... But my question is would this information be applicable to my home printer(Prusa i3) as well? Would I need to calculate a different number?

Always one step ahead! Retraction was going to be my next topic of discussion, but now that I have somewhere to start, I'll run another logo with the retraction settings on Monday.

Please don't feel like I ignored your reply about the backlash test with a cylinder, I plan on doing that on Monday also, the rest of my day today I have to print some replacement parts for a smartphone stand that didn't quite turn out so well.

Just an update.

Everything is running great! I finally noticed a problem with our right front pulley on the y-axis. The screw it sits on isn't very tight to the body and spins, so when the direction changes the pulley jumps a little bit. Not sure what I can do it though. After that I just aligned the screws that adjust the pulley and re-tensioned the belts. That including our new settings have us off to an amazing start now, great looking infill, smooth lines, it really looks great.

Today is exciting. Our CAD students design CO2 race cars each year, and one of us realized the software exports STLs. So when one of the students finished their design, we opened it in RH, changed a few settings in slic3r, and we're currently just over halfway through our first print and looking good!

Sorry it took so long to get the video, it refused to upload from my phone to youtube. I uploaded from my mac at work and here it is.

https://youtu.be/xoNA70geTxs

The first part of the video is the auto level, so skip to the about 0:40 to see the problem I think is causing some of our top fill issues. The pulley jumps a little bit when the direction is changed.

I can push on it pretty easily to get it to move just a bit.

Not good. Didn't take a pic but the top solid fill is just a grid pattern with spacing between each thread. Something seems amiss with our whole set up. I think I'm just going to pretend I just received the machine today, and run every single calibration test again. Because not many others are mentioning this problem, I have a feeling I might've messed up some of the calibration the first time I went through it.

1.1.7
I've tried several extrusion widths, from default to 0.48, from 0.21 to even 0.52. This last time I tried slowing everything down to 50% then 25% to see if we're running too fast but same issue. I have this sinking feeling my e-steps are off. Also I want to post a pic of our awful looking honeycomb infill. My last dual print failed because the 2 extruder clogged before use, I'll run a quick one shortly for a pic.

Also worth noting, although not sure it makes a difference, we updated the slicer that same with RH for Mac, because it was so outdated.