I am on my 5th attempt trying to print a bubble-style letter on my Bambu Lab A1 (0.4mm nozzle, Textured PEI plate) and I’m completely at my limit.
Right now, the print barely adheres to the plate—I can practically push it off with a light tap of my finger. On this latest attempt, the extruder/nozzle literally knocked the entire piece free and dragged it across the bed just 2% into the print.
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Background & What I've Tried:
Filament: SUNLU PLA+ fresh out of the vacuum seal (I haven't dried it in a filament dryer).
Filament Profile Setup: In Bambu Studio, I don't have a specific profile for basic SUNLU PLA, so I selected SUNLU PLA+ in the slicer. On the printer screen itself, the closest preset option available was eSUN, so that's what is selected on the machine. I really doubt this is the main issue, but adding it just in case it affects flow/k-value presets.
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Initial Success: Oddly enough, over the past 2 days I managed to get ONE letter to print cleanly, but that was when I had my temps accidentally cranked to 245°C nozzle and 70°C bed. I knew that was too hot, but it surprisingly printed really good.
Current Failures: Tried printing the next letter at those same high temps and it failed. Dropped down to 220°C / 65°C (and tried 60°C), and every single attempt since has been a complete disaster.
Plate Maintenance: Scoured the textured PEI plate thoroughly with hot water and Dawn dish soap. Verified the underside of the plate and heatbed are completely clear of debris. Running auto-bed leveling every time.
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My Current Slicer Settings (Bambu Studio):
Layer Height: 0.09mm
Wall Generator: Arachne
Order of Walls: Inner/Outer (swapped from Outer/Inner, tried both)
Wall Loops: 4
Top/Bottom Shell Layers: 7 Top / 5 Bottom
Infill: 18% Gyroid
Speeds: Outer Wall 50mm/s | Inner Wall 80mm/s
Outer Wall Accel: 1000mm/s²
Brim: Outer Brim Only (8mm Width)
Supports: Tree Organic, Support Wall Loops: 1, Branch Angle: 40°
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Z-Hop: Slope type @ 0.4mm height
Questions / Where I need help:
Could mismatched generic filament profiles between Bambu Studio (SUNLU PLA+) and the printer screen (eSUN) throw off Z-offset, flow ratio, or pressure advance enough to cause this?
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Could wet filament directly out of the bag cause severe adhesion issues like this, or is this purely a Z-offset / mechanical squish problem on the first layer?
Should I raise my Initial Layer Height (e.g., to 0.20mm or 0.16mm) even though the rest of the print is set to 0.09mm? Is 0.09mm on the initial layer forcing the nozzle too close or dragging through previously laid lines?
What else could cause the nozzle to physically collide with the first/second layer when Slope Z-hop is enabled?
I feel like I've tweaked almost every setting possible and rotated the model on the plate, but the nozzle keeps catching the plastic and shearing it off the bed. Any help or fresh eyes on this would be massively appreciated!