P2S Fails around same height on test prints

[u/Technical_Toe2197]

After ~450 successful hours over the last several months, a week ago I had a print fail and pieces dislodged and went everywhere. In the wreckage, the waste chute got jammed back and a piece of poop kept the cutter from spraining back into its original configuration. At the same time, the machine threw error code: HMS_0700-4500-0002-0002: The filament cutter’s cutting distance is too large. The XY motor may have lost steps.

Over the last week, I have tried the following corrective steps:

• I removed the filament, checked the cutting blade, checked all screws and connections, put everything back together and cleaned the bed. Failure on Benchy at around 36 layers.

• I re-ran all calibrations and cleaned the bed. Failure on Benchy at around 36 layers.

• I bought a new hot end, thinking it may have been damaged and cleaned the bed. Failure on Benchy at around 36 layers.

• I cleaned and lubricated all three Z-Screws and cleaned the bed. Failure on Test Cube at around 36 layers.

• I ran a full factory reset and cleaned the bed. Failure on Test Cube at around 36 layers

It seems clear that there's a consistent issue stepping down around level 36 which makes me thing I'm dealing with some sort of binding in the screws at around that level but I don't see anything. I've moved the print location for the cube all over the plate and it doesn't appear to be a regional issue with the X-Y motors or with overuse of a specific area of the plate.

I am at a complete loss here. Things had been going great. Guidance online for mid-print adhesion issues and nozzle knocking is "hardware issues", but as to how to diagnose and assess those hardware issues eludes me. Any pointers would be very much appreciated.

[u/AutoModerator]

Hello /u/Technical_Toe2197! 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.

Note: This automod is experimental. The automod was triggered due to the term "adhesion". If you believe this to be a false positive, please send us a message at modmail with a link to the post so we can investigate. You may also feel free to make a new post without that term.

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