I think I finally figured it out.

I tried to get it working again tonight and it clogged up inside. When I pulled the ptfe tube out I noticed it was extra hard. So for sh**s and giggles I changed it out with the extra piece I had. And now it is working like a champ and just like I expect.

If the problem comes back I will let you all know.

So I am assuming these should probably be replaced every 1000 printing hours or so?

I am at a loss.

I have a Pulse D-111, upgraded to a full metal hot end.
I have been using .4mm and .25mm nozzles (New, old, Genuine, Cheap...)
For all of this I am just using PLA. I have tried expensive and cheap brands, 3D Solutech, Hatchbox, MatterHackers Pro, and an expensive one that I cant think of the name off hand.

My extruder pops because it cant push the filament through. This happens when I have retractions, and with the .25mm nozzle when it is doing it pre-print expunge. I also can not always just push filament though without it popping either with this nozzle. This also happens when I am using a .4mm Olsen Ruby nozzle a lot, usually after a retraction and move, but not during expunge. I am using the same settings I have used since dialing in my printer with the new hotend having NO problems. But now I do.

I have no problems printing with my .5mm cheap nozzle that I print a lot of less detailed things with, but these also have few retractions except moving from part to part.

It acts like the material is wet when it pops the extruder and I then get under extrusion, as when I have wet PLA it does the exact same thing, and usually is the only way I know my PLA needs dried. But this isnt the case as I have used a brand new roll, and dried filament.

What it 'appears' to be doing is the filament is cooling on the tip.

At first I was thinking it was my nozzle getting clogged. It happens on a rare occasion so I cold pulled several times on my Olsen .4mm. Didn't help.

Then I thought it might be the fan which was dirty or the heatsink just not keeping it cool enough do I cleaned EVERYTHING, except the inside of the hotend which is not really possible.

Then I thought, okay, maybe when I cleaned it up a couple months ago I ended up getting the nozzle too far down. So I reset the nozzle and hotend placement. But still does the same thing.

I also check to see if I screwed up my filament settings somehow, but the diameter and density are both correct in all the settings I have tried.

So, I am wondering if my thermister is going bad in some way, or maybe the inside piece of the hotend.

So, as my first line, I am at a loss. I don't know what to do to get this to work right. I don't want to spend any money and it just being a waste.

Slicer Settings work fine, at least for me, both Material and Quality.

When you open the Setting to edit them, you can click on 'Duplicate' to make another copy of the settings.
To change the name can be a bit tricky.... Click the Pencil Icon next to the name, then change the name, and click out of the box (Anywhere except the save button... This is key, otherwise it may not change the name), Then click the save button.
All of the other settings you change will automatically be saved.

4 Things to note...
When looking at your selected settings. First, any setting you change in either Quality or Material can be anywhere in the Slice Settings.
A Yellow Line on the left of the setting means it is set in the Quality settings, Orange is the Material, and Blue is Manual/Override User setting.

Also note, Manual User settings will often Stick with that selection of Quality Settings so make sure you check your settings if you have manually changed stuff.

So for your issues, I would say check to see what color the setting is coming from and edit appropriately.

The Export Settings option exports the Quality and Material Settings. If it exports printer settings anywhere I have not seen a way to import them. And it will only import a single setting at a time, at least with the version(s) I am using. I have not checked the latest.

A Side note with the Settings. If you are connected to the Cloud with MC/Matterhackers the cloud automatically saves all of your settings, Printer, Quality and Materials.

I just wanted to say that they have fixed my purge issue, and I am waiting for the Alpha to come out to test it. Can't wait, as the rest I have seen has fixed everything I had problems with in the previous versions.

Here is hoping!

I've never had a problem with the slicing itself, especially after learning why I got bad prints and other things. Just happened on the reason I was getting print shifts on the Z here recently and everything has pretty much fixed itself. It has been the program itself that has had consistent problems.

I hope most of the bugs from the previous release are fixed as I see at lease some of them are, however this another version that I can not use. I know this program can be better than this, and this is 90% a disappointment response. And this is even worse for me because of all the wonderful help I have received from Michael and Eric at Tech Support.

(I will post later at home, as I don't remember my github pwd)
When it does its original purge it stops at the end of the purge and pools a little then it moves around, usually back near the X,Y Origin, then goes to start the print. When it starts the skirt one of two things happen, first it is clogged. The second is that it doesn't start the skirt, then eventually goes after 2 to 3 inches of movement. When it does this it usually has strings that hold on and pull around. Then this stringing screws up the first brim edge or perimeter of the model.

I printed 3 items with this version. The first went okay... had the stringy problem but just pulled it off by hand. Second item it clogged on me twice and stringed out a couple times... But I finally got it going...

Then the third...
I tried to start but got tired of the ridiculousness of retrying to get a good first layer... So, I went back to the old version I have been using (2 stable versions back).... I started it up, went to bed leveling and it F'd it up. The X,Y starting point for the Mesh was off thanks to the new versions settings and cloud sync. It dove into my bed on the 5th point because the Y was off and just caused havoc from there. I am not sure why but it also decided it needed to try and move the Y direction again and pulled out my drive belt. Thankfully all items were manageable.

So I went back to the new version having spent another 45 minutes resetting things up.. and then another 20 minutes (give or take), until I finally got a good first layer.

So my question now is this,

Since this program is the only supported slicer for the Pulse, how is it that having issues in this, and the previous version are acceptable? These are not stable/release versions, these are at best, Beta versions.

Last night, if it had been 10 minutes earlier I would have been on the phone with tech or sales support, and I guarantee it wouldn't have been pretty as I was ready to send my pulse back because of this. When you have a product that essentially relies on another product to work, you cant have a nonworking piece, and for the past 4-5 months, that is exactly what there has been.

Thankfully from previous experiences, I knew how to handle the issue and am now running back on the old version successfully with only a pit in my buildtak at the area I rarely print at. And I admit, I should have known better than have my syncing on in the new version so it wouldn't have F'd up my settings. I also admit for the last few weeks I haven't been looking to see if there has been a beta version to test, as honestly I really haven't had the time.

Wow.

Whatever changes you made to the slicer in 2.19.2.10169 sped up the slicing majorly. A 1562 layer slice too me about 12 mins compared to the over 30 mins it was taking me with the OLD version 2.18.1.10116.

Compared to 2.19.2.10157 a couple test slices that took about 50% longer, it's about 50% shorter in 169 just as my extra large model. I can now slice and reslice when exporting for the moment. Hopefully all of my test slices will come out as fast.

And thank you for fixing the Memory Bug I reported!

I finally had time today to download and test the new support system. I downloaded the Release version, not the release candidate. I have spent the last 3 hours messing and testing stuff with it and comparing to the old version, 2.19.1.10116.

When I use larger pillar (3-4) settings it does not generate the needed supports and leaves whole areas without.

When I use a small pillar (1.5mm, 2 still not small enough to get good supports) setting it does not connect the pillars so some supports are useless. On one model it added in an interface layer in mid air (no support), though I get this on occasion with the old version as well. But with some slight tweaking to my model the support this version generated was near perfect (Will Print this model). The old version did about the same for supports.

Furthermore the slicing time now takes longer than the old version. At least for the few objects I tested. On average I would say about 50% longer but it is hard to tell exactly as I have to run on different machines. Smaller supports the longer it takes to generate.

And since the 'Support Everywhere' option has been taken out I can not even use this for my prints. I know I can manually add supports in to take care of the issues I have but that defeats the purpose since the old version works better for the most part.

Before the following I did a couple small test prints that didn't take too long with no problems.

(Note: This is the model mentioned previously about the supports)
Now here is what PISSED me off. I went to print a large detailed model. I Sliced it and checked it before printing. I made NO changes to anything and hit Print, and it went to reslice it. It took 18 mins to slice it the first time, now another 18 mins to reslice it. The old version took about 13 mins to slice, and it never resliced anything unless I made a change.
Finally went to print but it had pull up on the brim so it was a failed print. AND THEN IT WENT TO RESLICE AGAIN!!!
This is a MAJOR EPIC FAIL for a release version.

On the brighter side it uses noticeably less CPU/Memory, as previously my sliced parts would have issues as I moved around making sure it created supports it needed. This version is MUCH better.

Also, the slicer appears to have a better algorithm as the pattern was nicer in the new version than the old (at least the first layer before it failed on me and....).

Great, thank you!

Most of the situations I have had to modify the STL are like Eyeballs, and places where the two intersect multiple times. By the time I separate the objects I can just as easily merge them. This is especially the case when 1 object intersects itself.

I love all of the 3d printable items that are out there to download, but some of the real nice looking ones are a pain to print correctly because of this issue, and a few others.

This only applies to STL's that have merged objects. MC handles everything well with it's own objects.

Where 2 objects intersect it creates a negative space. The slicer appears to think this is an exterior space instead of an intersecting objects that is actually another interior space.

I have been manually editing any stl's I have downloaded that have this situation, once I figured out what was happening, merging the two objects creating a single interior space. I have also used MC Primatives when I can, which also solves the issue.

I can see reasons for having valid negative space.
Does or will MC have the ability to ignore negative space in the objects without me having to change the STL's?