What I am not seeing yet is a clean isolation path.
Because the printer is not loading filament before the print starts, I would not start by assuming the model is corrupt. A bad model can cause strange toolpath behavior, but it usually does not explain the CFS failing to load filament before extrusion begins.
My first checks would be:
- Confirm this is not a slicer/profile issue.
Create a simple 20x20x1 mm high cube primitive, slice it with the same printer/CFS profile, and send that job. If the cube also starts without loading filament, the model is probably not the issue. That points toward the slicer start G-code, printer profile, CFS selection, or firmware macro behavior.
If the cube prints normally, then go back to the original model:
- Export it as a single STL.
- Start a new project.
- Re-import the model.
- –or–
- Repair or simplify the mesh if needed.
- Re-slice and test again.
- Separate the printer-side feed path from the CFS.
Remove the PTFE tube between the CFS/buffer and the printer, then run from the manual external spool. If it feeds and prints normally, the extruder, hotend, and printer-side filament path are probably OK. That shifts attention back to the CFS, buffer, slot selection, or the commands being sent at job start.
- Test the CFS one slot at a time.
Remove all spools except one known-good spool. Test each CFS slot with that same spool. That helps separate a bad slot, bad spool sensing, bad filament path, or slot-selection issue.
- Check the less common causes.
If the above points back to the CFS, check that the CFS cables are fully seated and that the slicer is actually assigning the print to a valid CFS slot/material.
If you strongly suspect firmware, the practical test is to roll back to the last firmware version where this did not happen and see whether the problem disappears.