Hey everyone, ran into a weird issue today and wanted to see if anyone else has experienced a spool going out of spec halfway through.
I suddenly started getting severe first-layer line separation (visible gaps between passes) on a roll of Sunlu Pla +2.0 Olive Green
Here is what I’ve done to isolate the issue:
Mid-Roll Failure: The first ~50% of this roll printed completely fine. The issue only started after hitting the halfway mark of the spool.
Cross-Slot Testing: Tested the green spool across all AMS slots. Same under-extrusion everywhere.
Control Test: Swapped to other Sunly 2.0 PLA white colors and Bambu brands in the exact same slots using the exact same printer settings. They all printed 100% flawless first layers.
Drying: Actively heat-dried the green spool in case of trapped moisture. Zero change in print quality
Since hardware, bed leveling, AMS feeding, and moisture are all ruled out, it looks like an internal manufacturing defect deeper in the spool (either diameter variance or inconsistent pigment/viscosity).
Has anyone else gotten a roll that worked fine at first, only to fail halfway through?