Under-Extrusion Due to Filament Spool Tangles

Under-extrusion can occur when the filament spool becomes tangled, creating external mechanical resistance that prevents the extruder from pulling material smoothly. Unlike internal nozzle clogs, this issue originates outside the printer's hotend.

Diagnostic Indicators:

• Extruder Noise: The extruder motor may produce a clicking or grinding sound as the drive gear slips against the filament due to the inability to pull it from the spool.
• Spool Resistance: When pulled by hand, the spool feels jerky, tight, or completely locked, indicating a knot or overlapping coil.
• Print Quality: The print exhibits missing layers, thin lines, or gaps, while the printer's motion system continues to operate normally.

This condition is typically caused by improper storage, spool overrun during fast retractions, or failing to secure the filament end, which allows the line to slip under a coil.

Sources

• qidi3d.com
• bambulab.com
• reddit.com
• prusa3d.com
• reddit.com
• simplify3d.com
• bambulab.com
• youtube.com
• reddit.com