[HELP] PrusaSlicer and Klipper (mainsail) ERROR: Move exceeds max extrusion | SV06

Hi everyone, I figured I have struggled with this enough over the past day and its time to consult the community. I’ve been running this same setup for about a month now with the only major change in that time being implementing the input shaping. Recently (last week) I have been unable to complete any prints because every time, I get the error: Move exceeds maximum extrusion ((in the case) 10.681mm^2 vs 0.640 mm^2).

My research says that it is likely due to a mix up between relative and absolute extrusion mode, however I did not change any of those settings in the past month prior to the start of this issue.

Troubleshooting conducted so far: 1) uncheck relative extrusion distances in printer settings>general RESULT -> same error. 2) re-enable relative extrusion in the slicer and explicitly add an M83 command to START_PRINT macro RESULT -> same error. 3) disable the check altogether and observe the print by adding MAX_EXTRUDE_CROSS_SECTION of 50 into printer.cfg RESULT -> no error, but it is massively overextruding blobs in that spot as expected given the error. Had to cancel print anyways it was so bad.

Edit: T.S. continued: 4) setting pressure advance to 0. RESULT -> same error.

Here is my START_PRINT macro before I started messing with it troubleshooting.

Pressure advance is 0.0425.

I’m not sure if there is more information I would need to share that may help find the cause like perhaps export the profile from the slicer as well?

I’m on PrusaSlicer 2.6.1 appimage on pop_OS using the Ellis 3d Sovol SV06 SuperSlicer profile adapted to PrusaSlicer with some tweaks as I go.

Printer is an SV06 running Klipper on a Raspberry Pi 4 with MainsailOS.

Nomad,

Purge line too long moving out of print space?

Nomad,

Also this is probably a problem in your printer.cfg

callcc,

Could you share the top few lines (including the first few G1 … Lines) of a gcode file that fails?

TheSun,

sure thing, here is the start of it.

callcc,

Hmm, can’t see anything wrong with it unfortunately. I’m also not used to Klipper G-Code (yet).

callcc,

You could also have a look at the few lines of G-Code that seem to trigger it. Although finding that line is not so easy. I’m just wondering if you would find an unexpected jump in the E coordinate ie. E jumping to E. That would at least make sure that the slicer is the culprit. If you don’t find such a thing, I guess your printer is badly configured somehow.

rambos,

Move exceeds maximum extrusion (1.531mm^2 vs 1.440mm^2)

This was solved by reinstalling slicer (Cura in that case) for one guy on the internet.

So maybe just install cura and try

TheSun,

I’m not really looking to change slicers at this point. I’ve used Cura in the past and have landed on PrusaSlicer for a variety of reasons and would like to get it working properly again ideally.

rambos,

Thats cool, but installing cura takes few mins and it might prove that you have a slicer issue. I just thought its easier to install cura instead of reinstalling prusaslicer

CmdrShepard,

Not sure what initially caused your issue but try throwing a G92 E0 into your start gcode right after homing and also after any purge line you may have setup.

I’ve encountered this same error when trying to recover failed prints by restarting them at the failed layer. If you don’t tell the extruder it should already be some distance through the print, it throws out the exact same error. Since you’re starting at ‘0’ it needs to be told that.

atocci,
@atocci@kbin.social avatar

I was having a similar problem with my printer as well, and this is what solved it. I wasn't able to print 2 things back-to-back without restarting the firmware first.

TheSun,

Thanks for the suggestion. Just tested by adding G92 E0 right after the PRINT_START and PURGE_LINE macros and it still has the same error at the same spot; right as it goes around the circle part of the elbow on the second layer.

CmdrShepard,

Might be something wrong with the slicer. Try a different slicer and if that doesn’t work try a different file. I’ve had Cura updates break my gcode in the past.

You might manually look through the gcode file and see if you see anything out of the ordinary at that layer.

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