Troubleshooting PETG: Sudden extrusion failure mid-print on 5m pro w/512 hours
I’m using ELEGOO Rapid PETG Filament (1.75mm) with the stock HS PETG settings in orca-flashforge v1.3.0. It’s been printing fine for the past ~30 hours. However, during the last print (a 3x5 Gridfinity 42mm bin), extrusion suddenly stopped after completing the base and ~4mm of the walls.
Here’s what I’ve tried so far:
- Verified the filament roll had proper tension.
- Cut the filament at the top of the hot end and confirmed it moved freely in the feed tube.
- I checked the humidity of the filament, and it is 24%.
- Swapped in a brand-new roll of PETG.
- I set the nozzle temperature to 270°C and tried to load it, but very little came out.
- Used a 0.4mm cleaning needle to clear the nozzle—still no luck.
- Replaced the nozzle with a brand-new 0.4mm one. Loading produced a normal-looking purge.
- Leveled the bed and tried the print again. The purge line came out dotted and inconsistent, so I canceled the print.
- I removed the nozzle and pulled out the still-hot filament from the top. Using the cleaning needle, I confirmed that the nozzle was clear.
At this point, I’m stumped. Do you have any thoughts on what could be causing the issue or what to try next?
Posted Apr 15, 2025, 7:36 PM UTC
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