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Inconsistent layer stacking
Prints come out more or less good on my A5, but there is a problem with the layer stacking I cannot get rid of. Being irregular, I cannot quite attribute it to z-axis wobbling, at least as a single cause:
The effect is visible on the 3D-Benchy I printed for reference (Cura 4.0.0, 0.2mm, 10% infill, 100%fan with BlowHard3000; see attached cura-settings.txt). I'm using Marlin bugfix-1.1.x with S-Curve-Acceleration, Linear Advance and Junction-Deviation (though the layer stacking loocked the same with both the stock FW and Marlin 1.1.8 w/out the extra features):
The filament I'm using is extrudr PLA NX2 with consistent diameter. I noticed however, that the extruder wheel imprints itself quite noticibly onto the filament, transforming it from O-shape to D-shape. The more ridig e-sun filament shipped with the printer didn't show this effect as much, but the layer consistency wasn't better, either. I did pay extra attention to extruder calibration.
Over the last few months, I've applied a few mods to my printer to aim for better mechanical stability:
- Removed the spool holder from the chassis to keep the spool from picking up oscillations from the x-axis movement and feeding it back to the z-gantry.
- Placed the whole printer on simple vibration dampers.
- Replaced the bed springs with fixed nylon spacers (with internal threading to have a snug fit on the bed screws), using a BL-Touch for leveling.
While the first two helped with ghosting, the latter showed no obvious effects, neither for better nor worse. Unfortunately I only started printing 3D-Benchies after all those mods, so I have no objects that can be compared 1:1.
Since I installed TMC2208 I could hear the slightest grinding noise during movements but moving both the bed and the x-sledge by hand appears to be smooth enough. Nevertheless, I've just odered the set of higher quality bearings from AliExpress. Replacing the bearings will be a good opportunity to check the lead screws and the couplers.
Any suggestion on what else I could do to improve layer consistency is highly appreciated. Or is the quality visible on my 3D-Benchy already the best I could expect? What is the quality I can reach with the A5, can someone please post reference fotos?