I have a CR-10 S5. I was very happy with the way it was printing but all of a sudden it cant get past 1 hour of printing without the filament breaking in the extruder. I have caught it in the act, it will be printing fine then the extruder will begin to click. I paused the print which lifts the hot end off the build plate. I can easily pull the filament out of the hot end and the Bowden tube, it will still click in the extruder. I release the clamp on the extruder and pull a few inches of filament through, cut it off and feed it back into the Bowden tube and hotend. Resume the print and it will continue printing fine until the extruder gear starts skipping again (maybe another 10 minutes in).
When I pull the filament out of the Bowden tube after it has jammed I notice the end of the filament closest to the hotend is still nice and round, but as it gets closer to the extruder there are teeth marks in the filament and it is also flat.
- First few layers go down good - extruder doesn't start clicking until ~ 1 hour into print.
- I have tried releasing the pressure on the extruder clamp - which leads to the gear slipping on the filament and wearing it away until it breaks.
- I have tried with different filament (one brand new fresh from packet) - same result, I have tried drying the filament in a filament drier - same result.
- I have replaced the nozzle
- I have pulled the PTFE fittings from the extruder and hot end and nothing is blocked.
- The Bowden tube is pushed fully into the hot end and extruder.
- I have checked the extruder steps/mm and is okay.
The printer is in an enclosure and my ambient temperature is usually 30-40 °C, I'm wondering if the filament is getting heated up to the point where it is soft enough for the extruder gear to damage it?
Printing at 50 mm/s and 215 °C PLA , really lost where to go from here...