Any luck with this? I have the exact same issue

@williamlynn Please send us an email @ support@matterhackers.com

@brucegage I have had this problem on every slicer and for me it has to do with the z steppers and layer heights. Not all layer heights print the same. I had a 0.33 and 0.35 fail, but the 0.34 printed perfectly.

Also, just for fun, check your x-axis belt tension and the pulley set screw on the stepper.

I have active licensing for most of the slicer programs available to work with.

@jomiscli check to make sure the leads are still connected to your microswitch and to the board. If one of the leads is loose or no longer connected, this will be the result.

Oops! Wrong printer.

Pulse XE E-423
MatterControl 64bit version 2.22.04.11471
Windows 11

Are you measuring from the first couple feet of the spool or did you find this in the middle/end of the spool?

If it's right at the beginning, that makes some sense. You technically get a bit more than 1kg, and the last bit of the spool (which is the first filament you unwind) can have some irregularities.

I found it. Probe Offset in MatterControl is NOT the same as running M851. To elaborate:

In MatterControl,

is not the same as

Ran

->M851 Z-1

in the terminal and was able to run Z-Calibration and Print Level with probe.

Was this on a delta printer?

If so, home your printer. Then, release the motor tension and move the head down so that the nozzle is touching the build plate in the center of the bed. Go to the LCD and set Z=0. Then Re-home the machine and run the leveling again. Should be back to normal.

This might help, Pulse XE Printer:

Brown appears to be Z-Max power which would explain your Z-Axis issues. However you said your Z-Max was filled so this may not help.

It should load into MC without issue. Does it give you an error message?

Other software uses slightly different syntax in the gcode, so MC may not parse it for viewing the same way, but if you use the slider on the right and drag it all the way to the top, it should show you entire gcode in the 3D view panel

@pverdin This is likely happening due to curling which is why it happens once the overhang begins. I personally find success when I print PETG around 260c hotend and 75c on the bed with 100% cooing to prevent curling.

@mavin I pulled the tube out of the top of the HW. Ran a 100mm extrude from controls. Filament feeds down the tube just fine

Have double checked HE path is clean again, cleaining pin pushes all the way thru the HE and the nozzle

Any idea how far the tube should insert down into the top of the HE?

@mavin Disregard

Turns out the Hotend was dislodged, pushed up out of the bracket slightly and that caused all the errors

Also, you may wish to check the usb cable. The usb cable that came with my Pulse was defective.