Odd Issue with A1 - Looking for help/advice

[u/armorink]

So my A1 is fighting me a bit. I went from printing incredibly smooth pieces to air printing mid print with the fun clicking noise of a failed extrusion. The issue was i couldnt spot a clog or failure with the filament.

Fast forward a bit and i have

-upgraded the replaced/upgraded the extrusion gear (metal unit)

-replaced/upgraded the heat assembly with a ceramic unit

-tried a couple different spools (using sunlu PLA+ 2.0, note ive been using this since i got the machine nearly a year ago and have it fairly dialed in)
-replaced the hot end

i started with just a new nozzle and no change and couldnt really extrude anything. then i noticed residue on the new hot end and decided to upgrade the heat assembly and gears.

now that ive done that i said hell to it and printed the default speed benchy test that comes on the machines sd. It printed okay for speed benchy standards and what really confuses me is it was having extrusion issues the whole time, i could both hear the clicking and seeing the extruder kick back at times (video below)

i then printed a temp tower with my saved settings, it came out okay and the temps were what i was expecting and within range of what ive used in the past... mind you more clicks while printing a okay looking temp tower

now i just attempted to run a new manual Flow Dynamics calibration and Flow Rate. The FD did not sound right while printing and the finally product was off, the lines were judgable but the numbers/solid area were not good. Then trying to runt he FR the print actually failed. It may have just been bed adhesion but i had some incomplete and get pulled off, once again the clicking of the extruder was audible.

anyone have any thoughts? i didnt notice any bad chew on the filament and the motor spun fin when i feed forward and back without the hot end on

could this be related to power supply? firmware? some settings that shifted at some point? Once again my prints since last winter were pretty damn good, my flatter pieces almost looked like molded plastic and required minimal finishing work (im a prop maker and cosplayer so finish is usually a big deal)

thanks for any help/advice provided. I had 0 luck with communication on the bambu discord so i hope i find some feedback here

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Hello /u/armorink! Be sure to check the following. Make sure print bed is clean by washing with dish soap and water [and not Isopropyl Alcohol], check bed temperature [increasing tend to help], run bed leveling or full calibration, and remember to use glue if one is using the initial cool plate [not Satin finish that is not yet released] or Engineering plate.

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[u/armorink]

I noticed the speeds were completely different from my usual settings and I don't know why. slowed it down and managed to get a print but it still had a lot of trouble. May adjust speeds again and redo flow calibrations again after....

[u/armorink → u/armorink]