1 Topic by redoverred

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Topic: Tried for faster ABS extrusion, got tons of problems!

So, Tim recommended I bump the temp up from 194 to 204, bore out the nozzle to 1.8mm, and insulate the whole barrel. I did that and now I'm having nothing but trouble! Before, the filament would exit the nozzle, make a NICE loop, and get wound by the Filawinder. Now, it gets a ton of kinks and flails around all over the place.

It won't wind properly, because it gets stopped up on the sensor and then the filament just extrudes while the winder sits idle. If I sit there and manually guide the filament, I get it to work fine, but I'm absolutely not sitting there for 8 hours.

I tried everything I could think of, including using some PTFE tubing to act as a sort of guide, but nothing works! Eventually the filament always kinks up and starts to wind around and I have to stop the machine, cut off the filament, and start over with a spool of barely any filament! It's super wasteful.

I have my setup as shown here, but the box is flat rather than on it's side. I can't go back to 194 though, because I tried and it extrudes at or over 1.8mm and I'd rather not get jams as I print. What to do?

2 Reply by elmoret

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Re: Tried for faster ABS extrusion, got tons of problems!

Try turning the fan off, that should reduce the diameter and let you back down the temp as well without getting oversized filament. It also may help to make the loop deeper and wider.

Where is it kinking? Maybe post a couple photos?

To be fair I do all of my runs without a Filawinder.

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3 Reply by wahada

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Re: Tried for faster ABS extrusion, got tons of problems!

Hi,
From your photo it looks like your Filawinder might be positioned too close to the nozzle.
If the loop is too tight, the strain may be causing the kinking. My nozzle to Filawinder
distance is 24 inches. I could be wrong but I think Ian suggests a 18 inch minimum
distance.

4 Reply by redoverred

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Re: Tried for faster ABS extrusion, got tons of problems!

I will try out some of these things, but right now I don't have a filament spool available. I'll print a spool later today and get some photos when I am able. Thanks!

5 Reply by tonycstech

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Re: Tried for faster ABS extrusion, got tons of problems!

Find a good distance from filaastruder tip to filawinder PTFE entry tubing.

Good distance is not measured by inches or centimeters but with your own eyes and your digital caliper.

Filament should exit the nozzle straight down (in a perfect world) and continue straight for another 4-6 inches (double for PLA) before it starts to curve into filawinder PTFE tension tube.

If you have horizontal setup then filament exiting angle is bad and difficult to control by filawinder distance or by sag amount or by anything else.

Thats my opinion. You can ignore it if you wish.

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6 Reply by redoverred (edited by redoverred 2015-06-01 22:16:44)

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Re: Tried for faster ABS extrusion, got tons of problems!

Just to update, the problem is still sort of there but kinda solved (in a way). What happens is the filament gets a kink in it at the nozzle. When that kink reaches the filawinder entrance, it whips the filament around in a strange manner and more kinks are introduced into the filament. I can fix it by turning the temp down to 194 again, but then the filament extrudes at 1.85mm or so. Then, if I take the fan off of it, it starts with the problems again. I think I might have to order another standard sized nozzle if the filament ends up being too wide for my printer, but I have to test that first. I also get more filament per minute with the lower temperature.

7 Reply by elmoret

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Re: Tried for faster ABS extrusion, got tons of problems!

That's wild, I've never heard of or observed faster extrusion at lower temperatures.

Have you tried moving the winder and extruder apart as mentioned by tonycstech? You could also deepen the loop, that would reduce the average filament diameter.

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8 Reply by redoverred

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Re: Tried for faster ABS extrusion, got tons of problems!

elmoret wrote:

That's wild, I've never heard of or observed faster extrusion at lower temperatures.

Have you tried moving the winder and extruder apart as mentioned by tonycstech?

Well, I don't really have anywhere else to put them, unfortunately, and the shelving units they are attached to are as far apart as I can get. I don't know the cause of faster extrusion, but I can say that the lower temp somehow forces the filament to behave well and not get all kinked up, so it stays in a nice loop at the lower temp. I don't mind the lower temperatures that much, or the possible slower speeds I am getting, I am just happy that it works again! I was trying to get more filament per hour, but now that I think about it, it doesn't really matter much since I only have to extrude every few weeks anyways for the amount of printing I do. Thanks for all the help, and if my filament is too large now I'll be ordering a new standard sized 1.75mm nozzle in the future!

9 Reply by elmoret

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Re: Tried for faster ABS extrusion, got tons of problems!

It's my fault you have to order one at all, so PM me your order number so I can help out.

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10 Reply by redoverred

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Re: Tried for faster ABS extrusion, got tons of problems!

elmoret wrote:

It's my fault you have to order one at all, so PM me your order number so I can help out.

I was getting diameters of about 1.8-1.85 max from this nozzle, so I'll print a few things over the next few weeks and see how it does and also extrude a few more kilos after that to ensure it sticks to that diameter. If it is absolutely unusable, I will PM you, but I think that should be alright; I've seen people use diameters up to 1.85mm in the bowden e3d-v6, so I think it should be fine. I appreciate the help, if I do have issues I'll send this nozzle back to you so you can use it elsewhere since I know you said you use this diameter nozzle on your own machines.

11 Reply by redoverred

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Re: Tried for faster ABS extrusion, got tons of problems!

I printed a few things now with the filament. It reads from 1.77-1.83 on the digital calipers, but after careful calibration I have determined it's effective diameter for printing is about 1.785mm. It runs through my hotend and bowden tube just fine, so I'll keep the nozzle as-is. Thanks for all the help, Tim!

12 Reply by elmoret

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Re: Tried for faster ABS extrusion, got tons of problems!

Nice. That should be fine for just about any hotend on the market.

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