Model is a toolbox insert with 1mm walls. E3P used to print 1mm walls, now same stl prints about .5mm walls (still very clean for most of the print). The little fingertip ledges on the top edge (photo is cutaway view) were to make it easier to pull out of the toolbox; rounded profile to avoid a sharper overhang. When the walls were printing at 1mm, everything printed beautifully to the top including the fingertip ledges. Now with the .5mm walls, I get spaghetti at the handles every time. Looking for ideas on what to check/try next.

Changed the nozzle tip, in case it was worn

No notable resistance in the Bowden tube

Uninstalled and reinstalled Cura, resliced just in case. Filament size in cura is correct, and everything is standard print except I always turn off the raft. I did try regular and vase modes, no difference.


Installed a metal extruder, in case maybe the old one was worn out/cracked (it looked ok when I switched it out)

Created a new test stl from scratch with 1mm walls but shorter runs (smaller box) and the walls print at .7mm, in assuming the shorter runs are allowing more filament to come out(?)

I looked for an extrusion test on Thingaverse that would just leave the print head in mid air to see if the filament goes to one side (to check for a blockage even on the new nozzle) but didn't find one. Manual extrusion via pushing the filament at the extruder looks fine until the fan blows the hot filament.

Is the next step a temperature tower, even though it printed fine before work the same stl and settings? Is there any settings on the ender itself I should check in case they accidently got changed? Control/filament/E is turned off. I also tried 'restore failsafe' but I can't tell if it did anything.

I did have some thermal runaways, replaced with a regular thermistor once, got the same error so moved up to a threaded thermistor. Maybe it is underreporting the temp? Is there a way to measure it externally, or is the only option to step up a few degrees at a time and see if it helps?


Appreciate any advice on what to try next

Underextrusion, what to try next?