Filament Clog

I am having an issue that I cannot find solutions to when searching on the web. I suspect it is because I am lacking the right vocabulary.

I have a Creality K1 Max. I have successfully printed over 2 dozen prints of a personal design that I created. It is an 11 hour 16 minute print. I have successfully printed through 3 spools of filament when this issue started.

At around the 6-8 hour mark (mixed results here) the filament stops coming out of the nozzle. I’ve managed to narrow it down to the extruder: as the filament leaves the extruder and is “handed off” into the hotend, it bunches up or folds and jams up in the extruder. It’s almost as if the hotend stops heating for a minute. I just have to take the extruder apart and clear the “knot” and reload the filament, there is no clog in the hotend and it starts a new print with no problems for about another 6-8 hours.

The following list of things I’ve done to try to resolve this issue:
Upgraded the extruder
Upgraded the hotend to the new unicorn nozzle.
Rebuilt the Gcode file.
Played around with the temperature settings.
Tried new filaments.

I’ve tried searching on the web for solutions but I guess I’m not asking the right question. I don’t know how to “discord” and reddit doesn’t seem to have answers that match up.

I can provide a picture of the issue tonight if necessary but I’m scratching my head here.

Hello @Bobby_Kickliter …! :wave:

Welcome to the Creality Forum…! Creality

Let us know what temps and filament you are using as this could help figuring out what is going on.

First thing I would check though if you are using PLA is make sure the top cover is off so the chamber temp doesn’t get too high. This would cause PLA to soften and not be able to get pushed through the extruder…

Watch the Details page in Creality Print for the temp graph and see if that fluctuates too much which would be a temp sensor problem.

PLA filament can get you more detail if needed
200 was successful. raised it 5 degree increments up to 220 unsuccessful.

will take the top off and watch the details page and followup.

Top off was unsuccessful. Looks like it stopped extruding about 6 hours in.

Noticed at the time that I canceled the print, none of the 3 cooling fans were running.

Looked for the “Details” page in Creality Print. Can’t find temp graph history - just the present and last 60 seconds.

Could this be the control board on the print head?
Could this be the extruder motor? I only replaced the gearteeth, not the motor itself.