Bent shaft? Are the current ones straight?
Probably dumb brainstorming ideas but… Assuming just one of the pulleys/idlers is a misbehaving outlier that can’t be felt by hand spinning (after slacking off the belt tension).
Do you have a way to spot check and sense outlier vibrations/noise/heat generated via tiny accelerometer, microphone, flir or something else…
How the heck did a stepper shaft bend? We have thrown them (at robo3d) and they didn’t bend. That is nuts.
Maybe the other one is bent as well. It would not be much, half the distance the Y is moving.
I didn’t bent it, it came like this from China, I didn’t spot until installed that motor. It is probably that way from the factory
Someone dropped that one along the way lol
I will give it another try but I already did this like 3 times. I got otherwise perfect prints in PLA, PETG, TPU carbon and this is the only issue that drives me crazy 
Curios if the issue being me tightening pulleys onto shafts with notches, that can probably create tiny offset?
What speed/settings are you using? Recall you’re running fast. Am happy to try similar (will use white yellow pla, it’s the lightest colored Overture/Hatchbox pla I have).
Fast settings were to test limits. My day to day printing is 120mm/s for PLA and 70mm/s for everything else. I slow down for small perimeters, too. Acceleration is 3500 with some input shaping. I can share my prusa profile but you will have to tweak a lot like starting / ending gcode etc, your extruder specific settings
I really need to figure out what is up with my printer. I’m running 1000 accelerations to keep it from skipping steps. Stock marlin I believe was 3000 from Ryan and it would skip all over the place there. I believe it did at 2000 as well. Gonna have to do some testing and see if I can figure out why.
3500 is an acceleration my printer can continuously perform thru the length if 325mm bed without skipping steps. I did tests described in Determining Maximum Speeds and Accelerations | Ellis’ Print Tuning Guide
On shorter runs I can do 6000-9000 but that gets violent pretty quickly. My XY current is set to 1.2amp
Yeah mine should be able to do the same but it surly cannot lol. Going to have to dig in and figure out why.
The only reasons for skipping I think of is low amperage / belts tension
Everything 120mm/s? Walls Inside-to-Outside?
Something like…
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was… |
trying… |
Increasd XY current from 0.7A to 1.0A, will observe temp using the V1E thermal stickers. 0.6 nozzle, 0.3mm layer height. No input shaping, will see what difference that makes later.
Didn’t hear about thermal stickers. Basically, I printed motor mounts from CF-PETG so they don’t melt. 1.2A (I use 2A rated motors) that I set is pretty hot but nothing bad happened so far after I printed 5 spools in a row. Maybe shaft bent because it melted 
Interesting, will override my Outer Wall, Top Surface and Initial acc from 1800 to 3500 for this print.
Am using 500mm/s instead of 1000mm/s shown in screenshot of your settings.
Need to improve my settings (flow, temp, retraction, cooling?), my fan duct design needs improving too.
Am not seeing similar indent ripple artifacts related to belt/pulley/idler/bent-shaft. My belt tension is looser than I initially thought is needed. Counter intuitively, I loosened my belts after seeing Ryan’s belt tension at Open Sauce.
Camera lighting and distance make a big difference… This is without doing recent temp/retraction towers. Goal was just to see belt ripples, which are minor for my relatively untuned build.
40c on the XY Steppers’ Temp stickers
Thanks for checking. I had these rippling at any speeds, even super slow and with any material
I just ordered a new set of toothed pulleys and idlers from Ryan, also ordered a new belt. I previously used what was left from a previous build, let’s see if Ryan stock makes a difference. Will report back
Did you solve your cooling issues? You have curling at 45 degrees, that can be cooling or temps or speed
No problem, good luck with the new hardware. Stepper shafts seem straight?
Curling was disappointing, am using this opportunity to update part cooling duct design to focus more air closer to, and below, the nozzle tip. Current fan is 5015 24v 0.15A… Might add larger, or 2nd 5015 fan if duct changes and temp/flow setting changes don’t help.
How are your curling/prints with other materials? PETG doesn’t need much cooling. Just to separate concerns, it may not be a cooling issue. when I was experimenting with different settings and fun ducts I figured cooling doesn’t play a huge role
