Overview
When using the S1 Plus in your 3D printing setup, it’s important to understand how its operation can affect long-term printer maintenance. The S1 Plus applies a constant preload force to the filament during printing to ensure smooth, uninterrupted feeding.
While this preload is essential for reliable operation, it can also contribute to increased wear on certain parts of your 3D printer compared to normal use. Components such as extruder drive gears, PTFE tubes, and filament sensors may experience faster wear depending on:
- Preload setting on the S1 Plus
- 3D printer design and extruder type
- Filament material and abrasiveness (e.g., glass-filled or carbon fiber filaments can increase wear)
Regular inspection and proactive part replacement will help ensure your printer runs smoothly and consistently, even with the added reliability of the S1 Plus’s automatic reloading system.
Bowden Tube Wear & Replacement
What to look for
When using the S1 with a 3D printer, the constant preload force applied to the filament can cause increased friction inside the inlet Bowden tube compared to normal operation. Over time, this may lead to wear—especially in setups with sharp bends in the filament path.
Signs of Bowden Tube Wear:
- Thin or worn sections along the tube wall.
- Holes in the tube—this can cause filament to be pushed out of the hole, creating a tangled nest of filament outside the tube. This happens because the S1’s constant preload continues feeding filament even when the path is compromised.
If any of these symptoms appear, it’s a good indication the Bowden tube should be inspected, cleaned, or replaced.
Improving Reliability
To extend Bowden tube lifespan and maintain smooth operation when using the S1:
- Avoid Sharp Bends – Keep the filament path as straight and gradual as possible. Sharp turns dramatically increase localized wear from the preload force.
- Use Minimal Necessary Preload – Adjust the S1’s preload to the lowest setting that still ensures consistent filament feeding.
- Inspect Regularly – Check the tube’s condition during routine maintenance and replace it at the first signs of wear.
- Consider Nylon 6 Tubing – If PTFE tubes wear out frequently, Nylon 6 is far more wear-resistant. However, nylon tubing is also stiffer, which may require modifications to your printer’s filament path or tube mounting to ensure smooth operation.
- Keep Tubes Clean – Dust and debris inside the tube accelerate wear. Use filament cleaning pads before the S1 Plus inlet to help keep the path clear.
Extruder Gear Dust and Cleaning
What to look for
While not typically caused by the S1, filament dust buildup in your 3D printer’s extruder gears can lead to filament reload failures. If the gears become packed with dust, they lose their ability to properly grip the filament.
When this happens, the extruder may not be able to pull filament through the S1 and the inlet tube that connects the S1 to the printer. This issue is made worse because once filament leaves the S1 gearbox, the S1 can no longer apply additional pushing force—meaning the printer’s extruder is solely responsible for pulling it the rest of the way through the S1.
Improving Reliability
- Keep the printer’s extruder clean – Regularly inspect and clear any filament dust from the drive gears.
- Reduce tube friction between the S1 and the printer by:
- Shortening the inlet tube where possible.
- Avoiding sharp bends in the filament path.
- Using 2.5 mm ID tubing instead of 2 mm ID to lower friction and feeding resistance.
A clean, low-friction filament path ensures the printer’s extruder can grip and feed reliably, helping the S1 complete reloading cycles without interruption.
Secure Bowden Tube Connection
What to look for
Over time, the Bowden inlet fitting on a 3D printer’s extruder can wear out, loosen, or fail to hold the tube securely. When using the S1, the constant preload force on the filament can cause a loose Bowden tube to pop out of the fitting.
This can create a tangled nest of filament outside the tube. This happens because the S1’s constant preload continues feeding filament even when the path is compromised.
Improving Reliability
- Regularly inspect the Bowden fitting for wear or loss of grip and replace worn fittings as soon as they show signs of failure.
- Use a high-quality Bowden fitting like the ECAS04 designed for strong, long-term grip.
- Add an additional adapter or 3D printed support to reinforce the connection if the fitting is prone to movement.
- Install a press-fitting lock to prevent the tube from being pulled out during operation.
- Ensure the tube is cut clean and square before inserting it into the fitting.
A secure Bowden inlet ensures that the filament path remains sealed and stable, allowing the S1 to preload filament without risk of the tube coming loose during operation.
