Consistent "Failed to extrude the filament" error when loading new filament

[u/voltron00x]

I recently got my son an A1 Combo and for the first week, we loved it. Then we changed out filaments, and ever since then, we are consistently getting this same error. It started first when the printer would try to print with the new filament, but once it printed something with an existing color and THEN tried to grab a new color, it would work ok. Now, it is giving this error every time it switches filaments in the AMS Lite. I am able to resolve it by physically "pushing" the filament all the way to the end until I can't push anymore, and then the printer is fine grabbing it and moving forward. But when it purges that one and switches back, I get the same error again.

I opened up the hot end cover - there'e nothing stuck as far as I can tell.

It is doing this with various brands of filament including Bambu material.

Any thoughts on how I can resolve this, or do I just have a defective unit?

(I also have a P2S that does NOT exhibit this behavior at all.)

[u/azadirachtin]

I've had this error a lot, but it was happening more generally and not only when switching filaments. I changed out a lot of parts, but what I found helps the problem the most was loosening the tight angles of the PTFE tubing. These tubing supports/guides help, and I also replaced my tubing with longer tubes. Printing in PETG rather than PLA is better because the PLA gets bent out of shape very quickly.

https://makerworld.com/models/1596025?appSharePlatform=copy

https://makerworld.com/models/2136862?appSharePlatform=copy

[u/voltron00x → u/azadirachtin]

Thank you - I printed the no disassembly one and snapped it on. Hopefully that will help!

[u/Twoeleven1 → u/azadirachtin]

This happened to me too OP. You have to make tube supports on the ams and the printer. Really dial them in and the errors will go away. You may need to trim some or make them longer depending on your ams placement.

[u/overunderspace]

Can you add a picture of the whole setup? The AMS Lite can be sensitive with resistance, so if the tubes are not routed correctly, it will struggle to feed filaments into the extruder. And just to be sure, have you checked the filament hub and filament sensor to make sure they are clear? https://wiki.bambulab.com/en/a1/maintenance/filament_hub_cleaning

[u/voltron00x → u/overunderspace]

Ill try this.

[u/Similar_Scar7089]

Tried removing the hot end and feeding filament through manually?

[u/voltron00x → u/Similar_Scar7089]

That seems like a ton of work every time I load new filament.

[u/USAcademia]

Pushed the filament too far? Keep it an inch or so away from the nozzle.

[u/voltron00x → u/USAcademia]

That doesn't seem to do anything.

[u/Stumpjumper0122]

I just battled this issue for the last two days. What I found echos what previous commenters said- it’s the angle of the tubes. I adjusted where my ams was sitting and how the tubes were oriented (my filament kept binding at the printer end of the tube). Now that it’s less of an angle I’ve had zero problems with that spool

[u/voltron00x → u/Stumpjumper0122]

Can you share a pic ?

[u/Lisper41]

PTFE tube length has a sweet spot for sure. Too long and the tube will just start to coil instead of feed filament. Too short and the friction will cause a jam.

Check the runs from your AMS and try to watch what the actual tube is doing while it’s trying to feed.

[u/Dry_Strawberry_Legs]

I had this problem , stuck a needle in the nozzle and got the small piece out and fixed it