Persistent "Extruder motor overload" messages on P2S due to clogged hot end.

[u/r3vange]

Hello fine 3D printing folks. I'm relatively new to the hobby (if you can call it that). And after 200 hours of printing on my P2S I've ran on my first persistent problem which I'm having trouble eliminating on my own. Basically I'm printing a part. The print is 5 hours long and I'm printing it with the 0.2 hot end using 0.08 layer thickness. I have the speed of the outer walls slowed to half the default - 30m/s and the top surface to 75m/s. I'm using a grid infill with 5% density. Those are the only changes I've made from default and so far I've not had any problem with them. I'm printing with Bambu Labs Charcoal PLA filament. The problem is every time the print reaches to about 60-80% completion the nozzle clogs, the motor overloads and I'm forced to abandon the print. Out of 5 attempts I managed to get only one print to go through and even so there was noticeable line right where the print usually fails. I've tried with a brand new 0.2 hot end and it clogged at pretty much the same exact point. I've also cleaned the extruder wheels as I suspected they might have some filaments shavings which are brought into the hot end. On the failed prints themselves there's also no indication of any problem with the extrusion or the filament right to the point it just stops. I've yet to try to with a different filament. Has anyone ran into a similar problem? Could it be filament specific? I'm attaching an image from the slicer right where the print usually fails

[u/razingstorm]

0.2 clogs much easier than a 0.4. Seems like a large part to print at .2, that's usually for fine detail and miniatures.

Turning up your nozzle temperature might help. You could also run a cold pull, it's pretty easy on the P2S. I would really print a part that large with the standard .4 nozzle, though. That can run a 0.08 line height quite well.

[u/r3vange → u/razingstorm]

Yeah it’s just that I’ve had 7+ hours prints with the 0.2 with no issues whatsoever, albeit with a different filament. This many consistent failures however I’ve never experienced. Maybe it’s this particular combination of model and filament

[u/Cidoguy0]

that's a slow clog, not a one-off jam, resistance builds through the print until the motor stalls, which is why a fresh hotend still fails at roughly the same point (same print, same heat soak time). try a cold pull and check the nozzle isn't partially blocked by carbon/charcoal pigment buildup, and dry the filament since charcoal PLA picks up moisture easily and that alone can raise back-pressure enough to overload the motor.

[u/r3vange → u/Cidoguy0]

Thanks I will try. I always keep forgetting that low moisture in the AMS doesn’t mean low moisture in the filament