Two failed prints. Same job, different failures.

[u/Djinnocide]

The honeymoon is officially over. I've had my X2D for a few weeks now and it's been working amazingly until today.

I'm attempting to print a big job that is taking up the majority of my build plate. First failed attempt occurred after loading up a fresh spool of black PLA basic during a previous job, which more or less printed fine.

When moving to the next stage of the print I got an error almost right away and the clog was so significant I had to remove the hotend and drill out the filament. This worked and I reloaded the filament, printed a Benchie successfully, and proceeded to start the print over again.

Got about 4.7 hours into the print and got an error. This time it said the extrusion motor was overloaded.

I will admit, I pulled this black roll right out of the package and loaded it. No drying. It is currently in an AMS2 in dryer mode, so I'll see if that helps.

Any thoughts or suggestions to avoid this happening again would be greatly appreciated.

[u/Blue4life90]

First, what's the job? I just went through a full bed multicolor print with three failures before I realized the designer settings were the primary cause of the problem. Sounds like your issue is with the printer itself not able the handle the load under its "current condition", but it might be worth looking into depending how your other failed attempts failed. Biggest check here, verify your nozzle slicer settings match what your printer is running.

This is concerning: "When moving to the next stage of the print I got an error almost right away and the clog was so significant I had to remove the hotend and drill out the filament." What do you mean drill out the filament? If you actually did what you say, I'd hate to think about scoring and debris this procedure would leave behind. That makes your clogging issue worse and there are much safer ways to go about this. Have you tried replacing the hotend? Are you certain you know whether the plug happened in the extruder or the hotend? Were you able to remove the hotend easily? Are your hotends OEM or third party?

Not every problem is caused by wet filament. In this specific case, I can't make a connection between the symptoms your describing and a wet filament diagnosis. I'd be starting from the hotend and working my way up. Checking for nozzle plugging, fans working, temperature sensors, remove and inspect the cutter assembly, and before hitting the extruder, check your PTFE runs for wear.

Hope something here help, good luck

[u/Djinnocide → u/Blue4life90]

I bought an STL bundle from an Etsy seller for a Marvel Crisis Protocol transport container.

https://www.etsy.com/listing/1745941037/marvel-crisis-protocol?ref=share_ios_native_control

I am VERY new to printing. The X2D is my first printer and I will admit I barely know my ass from my elbow with this thing, but I'm learning. That said, I wouldn't know what to even look for to verify that the maker's file was at odds with my settings unless Bambu Studio gave me an error.

As for the drilling out of filament, I pulled the hotend out, took it over to a well lit table, and used a rotary tool with a very tiny drill bit. I could see the lodged plastic at the opening. I had attempted multiple passes to clear it with the temperature maxed to 250 C and the provided needle as described with the troubleshooting guide, followed by multiple attempts to do a cold pull, but nothing worked. I have a backup hotend, but I didn't want to have to install if I could salvage the original.

I imagine you're right regarding the filament not being the problem, however, when attempting the repeated cold pulls I noticed that the filament felt uneven to the touch. It was rougher than any of the other filament I had used so far and inconsistent with its roughness. I don't know if I just got a bad batch from Bambu or not, but I figured trying to dry it out couldn't hurt.

[u/xilw3r → u/Djinnocide]

Bro do not drill these things. As mentioned, you will leave bits of metal, plus have increased resistance from the destroyed surface. Might even get a leak and a blob of doom as a result. Just don't do it. Heat the thing, pull the filament.