07/24/25 02:57PM 3D Printing - Prusa XL

Issue type: Equipment Problem
Area: 3D Printing
Equipment: Prusa XL
Summary: Extruder 2 is misaligned
Additional Info: It seems to be mis-calibrated in Y

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The blue letters are printing overlapped with the white around them.

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I spent several hours last night attempting to adjust this, both using the automatic calibration routine and manual adjustments. Extruder 2 is now much closer to alignment with the other extruders, but it’s definitely not perfect. You can still see light through gaps in a two color print. I think there’s still a misalignment of ~0.4 mm.

I think the next step is probably swapping out the nozzle on extruder 2 and trying the automated calibration routine before we do any printing with it so that it is completely clean.

If that fails, another few rounds of manual adjustments are probably necessary.

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It looks like Extruder 2 suffered a big hit of some sort. The nozzle that was in there was visibly not square. I don’t know if this was a tool crash or the extruder being dropped, or what. Replacing the entire hot end fixed the problem.