I decided to splurge with the money I got for my birthday this year. I upgraded from a PowerSpec i3 Mini I've had for years, all the way to an Ender 3 S1! The Ender 3 is very quiet so I can do bigger print jobs all night on the larger print bed (I have to keep everything within my bedroom and the i3 likes to "sing" while it prints). The heated bed is an absolute dream come true- no more painter's tape and glue sticks! I can print in filaments other than PLA too and everything that I've printed so far has seemed sturdier (though I've yet to really put the two head to head).
There is just one issue though: I can't get it to make my print-in-place hinges.
It seems to have taken issue with both the print-in-place files I've tried. The first one was actually the first print job I did with the printer, it was a little collapsing dagger (it's like those toy light-sabers you used to wack your friends with). It doesn't seem to extend out all the way and two of the sections seem stuck together, quite weird considering there was no need for supports. I might have to revisit this model because I only tried it one time.
On the other hand, I've tried my print-in-place hinges several times with several different settings with a couple different PLA filaments, I even tried printing it in TPU! The thing is I know these should work, the i3 did a great job making a few of them and I not exactly willing to just swallow the notion that my new Ender can't outperform it in every way. I've tried matching the settings from the i3 .GCODE compiler (which might not be entirely correct, but even then I ought to be able to get away with a high resolution model with no support.
I've tried to think about every difference between the two printers and I just can't fathom how the Ender could fail at this task. Maybe the heated bed is keeping the knuckles and pin just warm enough that they end up sticking together, but I really doubt that- or at least I really don't want it to be true. No matter what I try the Ender hinges just end up breaking, they are too stiff. The i3 hinges are a little tight at first but they give and start swinging freely once you start working them around a bit. I still think it could be something in the settings, but I have a hunch I might be going about it the wrong way. So if start I getting too desperate (and no one has any better ideas) I might just try reducing some of the values in an effort to try and match the lower quality of the i3.
I just hope I can find a way to print stuff like my hinges on the Ender because the absurdity of having invested so much in an upgrade and it not being able to do something I plan to utilize more and more in my future projects is just revolting.
I'm attaching the .STL of the hinge for anyone who is curious, and I'll provide the .GCODE for either machine if anyone wants to take a look at them for whatever reason (not sure why you would). Just ask about any files that interest you. I'm rather proud of my work and I'm devastated that it isn't working with my new machine. I suppose I could always try to re-engineer it, but I feel like what my i3 can do my Ender should do better. Remaking the model would be rather easy, but I'm quite happy with how small I was able to keep the hinge's profile and it'd be a shame if I had to bulk it up a whole bunch.
It just annoys me because I know that these hinges can work, the i3 has proved it with four consecutive successful models (done in glow in the dark PLA ).
If the Ender can't cut it I suppose I'll have to make a standard hinge and just create all my future projects around them.
Sorry for belaboring that point over and over, I just think it's silly that my brand new machine is struggling with print-in-place while it exceeds standards in every other capacity.
I already was kinda planning to keep the i3, maybe keeping it boxed up in the attic until I have a need to print two models at the same time, but if I can't find any solution to this little puzzle I may end up keeping it right where it is.