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Constant filament splices failing and Error 131

I’ve been trying to do some test prints with the Palette 3 Pro and every time the print fails due to the filament breaking at a splice with simple PLA filaments. It works fine most of the time but it only has to fail once for the entire print to fail, which is exactly what happens. I tried a lot of different settings with Splice Tuning but it seems even with settings that work for most of the print, sooner or later a splice ends up failing. Sometimes when this happens the Palette gives an Error 131 and stops the printer, while other times the printer just merrily keeps on going even though it’s no longer being supplied with any filament.

It also seems that sometimes the tube inside the Palette device comes loose off of where it’s attached near the outgoing drive. I’m not sure if this is related to the first issue, but I can’t imagine it’s a good thing.

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After a bit of testing, it seems like the quality of the splices is super inconsistent. In a length of test material I had the Palette make for me, I can easily pull apart some splices with my fingers while other splices using the same material seem to be as strong as the filament itself.

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Same problem after new settings:

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Hey Dennis, which splice tuning values are you using on your most recent attempt?

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@jonnyyeu I'm not at the device right now, but if I remember correctly my last used setting was 4/2/4 for heating/pressure/cooling.

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Hey Dennis, do you mind trying try splice using 4,2,2 and seeing if you are finding success? Having 4 for your heating value might be a bit too high.

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@hana I’ve tried your suggested splice settings and I still got a broken splice inside the machine in the middle of a print.

[image|4371]

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@dmariman Sorry the image didn't upload properly. Could you please send it to support@Mosaicmfg.com and we'll take a look

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Thanks, Dennis. Could you please take your Splice Core out and flip it so that the pogos are sticking up? Do you notice if any of the pogos are loose?

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@jonnyyeu It looks fine to me, and none of the pogos are loose.

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Thanks for sharing. Could you please try a splice with 4/1/2 and share a picture of the splice with us? Also, please update Palette's firmware to today's release before attempting another print/splice

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@jonnyyeu I’ve updated my firmware and used 4/1/2 for my splice settings and I’m still having issues. The only significant change seems to be that I’m now getting error code 134 instead of error code 131 when I try to print. I’m assuming that’s because of the new firmware.

The quality of the splices is inconsistent. Compare the spliced parts in the attached picture (excuse the less-than-ideal picture quality, I’m having to use my phone for this). The one one the right looks the way I’d expect it to look, but the one on the left has a very thin spot. Both of those pictures are using generic PLA with the same settings. This matches my previous experience of most splices being fine, but getting unexpected failures halfway through a print.

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Thank you for sharing. Would you mind sharing a picture of a splice at (0,0,0)?

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@jonnyyeu I have tried 0/0/0 but it gave the same issues as 4/1/2 before. I’m sorry I didn’t take a picture, but it would’ve looked similar to the one I posted earlier anyway.

As an experiment I tried to go completely the other way and try 1/6/6 which actually seems to be giving better and more consistent results so far.

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Thanks for sharing. I'd recommend keeping compression lower if possible, as overcompression can sometimes lead to deformed splice tubes, which can then cause further splicing issues.

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I have this exact problem. The P3 gives dozens of splices just fine and then, bam!, a bad slice and whole print is gone.

I am using the latest firmware 21.12.07. I have tried several splice settings and nothing seems to solve the problem.

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Hey Bill, when the splices fail, are they necked splices, or cold splices (where there is no color drag and it seems as if no heat has been applied)? Also, what are your splice settings?

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I’ve started seeing this intermittently on my P3 - several prints failed when the filament necked down small enough that the extruder drive wheel couldn’t continue pulling the filament.

I’ve done a bunch of splice tuning, and generally end up with values around 1-2, but every so often, it seems like the two drives in the Palette get out of sync and the outgoing drive pulls forward just a fraction before the incoming drive pushes, resulting in the splice necking down to about 1/2 diameter (the necked filament section is about 2mm long)

On my most recent failed print, I noticed that this started to happen more often with one specific filament (still happens with the others, just happens more with this one) so will be doing some more testing. I’m wondering if somehow it’s not solidifying enough before getting advanced.

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Hey Zeno, do you notice if this is happening with specific drives? Also, could you please try and increase the cooling factor, as this could be due to the filament being molten when it is being moved along the filament path, causing it to neck.

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Thanks for the info!

Hmm I haven't directly noticed a pattern to which drive its on, but I will definitely do some testing!

I'll try the extra cooling, previously had it set to 1 but I'll try 2 or 3 and see how that goes.

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Glad and sad to see I'm not alone with this issue. Its the last hurdle to me getting to use my machine.

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Tried extra cooling. it sorta helped, but still seeing this (more intermittently with longer cooling) however, this has resulted in another issue.

Now, on certain prints where a given color is only used for a short period, I've had the printer trying to do it's purge between colors at the same time as the Palette is splicing the next splice, at the same time as the palette tried to do a Pong, which resulted in the printer pulling hard enough on the filament to make it slip in the Palette's outgoing drive, pulling apart the splice. I think this is probably a pretty extreme edge case, but definitely makes me worry about leaving prints running for long runs, since a pong like that could easily make the print fail. Would be better if the Palette sent a pause command if the printer was trying to purge during a splice, just to make sure it wouldn't run out of buffer.

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@zinventor Thanks for sharing, that does seem like a very rare edge case, but I'll forward this to our team. There is the option to slow down the print speed during a splice, and this would likely help to avoid this issue in the future.

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Dennis Mariman will be eternally grateful.
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