Overheating and Smoke Buildup

Creality Falcon Creality Falcon
1

Hello

I’m using a Creality Falcon2 Pro 40W. It stops running after 10 minutes at 90 watts of power and gives a high-temperature warning. Additionally, there’s a heavy buildup of smoke inside. I think the smoke extraction is insufficient.

Are any of you experiencing similar problems? How can I find a solution for this?

2
  1. Are you cutting or engraving ?
  2. What are you cutting/engraving? (please include item thickness)
  3. Are you exhausting directly out a window ? If not where does the exhaust route and how far is the tube length ?
1 Like
3

First of all, thank you very much for your response. Even your questions were helpful.

  1. I use it for cutting.
  2. I am cutting 2.7 mm MDF.
  3. The smoke travels through a pipe that is approximately 10 meters long. I vent it out through my house’s chimney.
4

I use my Falcon2 40W for cutting as well. I haven’t tried MDF but I have cut 6mm Baltic Birch. For a 10m long pipe you will need a very strong fan and it is best to have it placed near the exit/chimney so that it is sucking the air out of the house rather than trying to blow it through the 10m pipe to the chimney exit. As for the high temp warning…not sure. So far my longest cut was about 20min at 80% with no issues. Having a lot of smoke buildup inside may be throwing the sensors off. Do you have a closer window you could run the exhaust out for at least a test to see if that works without tripping the high temp sensor ?

1 Like
5

Based on your advice, I ran a few tests. In these tests, I tried to measure the effect of smoke, speed, and reduced power on the overheating issue. I performed the same cut for all tests. Here are the results:

Test 1:

  • Settings: 750 mm/min speed, 95% power, 1 pass.

  • Conditions: The enclosure was closed during the job. Smoke built up inside.

  • Result: It gave a high-temperature warning after 5 minutes. About 1-2 seconds after completing the 9-minute job, the alarm went off and the machine stopped itself.

Test 2:

  • Settings: Same as Test 1.

  • Conditions: The only difference was that I left the enclosure open, so no smoke built up.

  • Result: It gave a high-temperature warning after 6 minutes. Shortly after completing the 9-minute job, the alarm went off and the machine stopped.

  • The open enclosure provided a 1-minute improvement.

Test 3:

  • Settings: 15,000 mm/min speed, 90% power, 23 passes.

  • Conditions: The enclosure was closed. However, due to the high speed, very little smoke was produced with each pass, allowing the machine’s fan to exhaust it more easily, resulting in less smoke buildup.

  • Result: It successfully completed the 34-minute job with no high-temperature warning. I believe the reason it didn’t overheat was the airflow from the high speed, which cooled the laser head (like the cooling sensation when you wave your arm quickly).

  • I was not happy with the results. The pieces didn’t come out easily and would have required more passes. The cutting time was very long. The high speed caused distortions in the shape of the cut pieces. Instead of charring, it created fine wood dust that stuck to the top surface of the MDF and the machine parts. The charring on the edges and bottom was much less, giving a cleaner look.

Test 4:

  • Settings: 400 mm/min speed, 50% power, 1 pass.

  • Conditions: The enclosure was closed. Smoke built up, and the fan was insufficient.

  • Result: It gave a high-temperature warning after 15 minutes, but despite the warning, the alarm did not go off after the 16-minute job was complete.

  • I got my favorite results with this test. The pieces were cut well and I could remove them without difficulty. The job time was reasonable, and there was no shape distortion. There was much less wood dust; instead, there was charring, which I find easier to deal with. Compared to Test 3, there was more burning on the edges and bottom, but I can hide the bottom burns by cutting a symmetrical piece and flipping it over. The charring on the edges is not an issue for me; in fact, it even adds a nice aesthetic touch to some of my projects.

Also, based on your recommendation, I have ordered a fan. I hope to test it within a week and will likely share the results.

Your help has been very valuable, thank you again. I’m open to any further ideas you may have.

6

I am new to lasering but I don’t see a MDF setting in the Creality materials list.
Creality cutting/engraving settings/Materials list

If you cut something that is on the materials list does your device overheat ?
If you cut the sample 2mm basswood (or something else on the list) and it overheats, you should get in touch with Creality so that they can assist/resolve while your warranty is still good.

I did a query and AI gave me the following back (take this with a grain of salt as to the accuracy of the info)

"A Creality 40W laser module overheating can be caused by several factors, including a dirty or failing cooling fan, insufficient power supply, or issues with the thermistor or hotend. To address the issue, start by cleaning the laser module and its cooling fan, and check the fan’s cable for loose connections. If the problem persists, inspect the power supply, thermistor, and hotend, and consider performing a PID Autotune to recalibrate the system.

Here’s a more detailed breakdown of the potential causes and solutions:

  1. Cooling Fan Issues:
  • Dirty Fan: Dust and debris can accumulate on the fan blades and heat sink, hindering airflow and causing overheating.
  • Faulty Fan: The fan itself may be failing, resulting in inadequate cooling.
  • Loose Fan Cable: A loose or damaged fan cable can prevent the fan from receiving power.

Solutions:

  • Clean the laser module and cooling fan thoroughly, according to the Creality Wiki.
  • Check the fan’s cable for secure connections and damage.
  • Test the fan with an external power source to determine if it is functioning correctly.
  1. Power Supply Issues:
  1. Thermistor and Hotend Problems:
  • Loose Thermistor: The thermistor, which monitors temperature, may be loose and require tightening.
  • Damaged Thermistor: If the thermistor is damaged, it should be replaced.
  • Hotend Issues: The hotend, which houses the heating element, may be faulty and require replacement.

Solutions:

  • Tighten or replace the thermistor as needed.
  • Consider replacing the hotend and performing a PID Autotune after replacement.
  1. Environmental Factors:
  • High Ambient Temperature: High room temperatures can exacerbate overheating issues, especially during extended use.
  • Humidity: High humidity can also affect performance and component lifespan.

Solutions:

  • Ensure the laser engraver is in a well-ventilated area and consider using air conditioning or a dehumidifier if necessary.
  • Allow the laser module to cool down after prolonged use, especially in hot weather.
  1. Smoke Extraction:
  • Insufficient Exhaust: Poor smoke extraction can lead to smoke buildup and contribute to overheating.
  • Dirty Exhaust Duct: A clogged or restricted exhaust duct can also impede airflow.

Solutions:

  • Ensure the exhaust fan is functioning correctly and that the exhaust duct is clear of obstructions.
  • Consider upgrading to a more powerful exhaust fan or using a smoke purifier if necessary.

By addressing these potential causes and implementing the suggested solutions, you can effectively troubleshoot and resolve the overheating issues with your Creality 40W laser module."

1 Like
7

This might be related to the problem I have myself at the moment, but I have a cloth enclosure for my Falcon2-40W. It only has a 3" hose with a muffin fan. Using the basic 3" hose, and found the following:

  1. the intake fan, sits less than an inch from the Falcon2 frame. After cutting a piece of 6mm play. Not only did it not clear the smoke, it did not clear out the smoke after a minute. The length of pipe is maybe 5’ and goes directly outside through a vent.

  2. I then replaced the 3" hose with a 4" hose and 4" blower https://business.walmart.com/ip/RichYa-4-inch-Inline-Duct-Fan-with-Variable-Temperature-Humidity-Controller/1788506912. I have not yet modified the 3" port from the enclosure, nor the 3" external vent. I am planning on switching up a 4" vent and cut a larger 4" fume hole. Even with the proper exhaust fan, it still does not clear the smoke after a minute or more.

I am wondering the extra diameter and exhaust fans will work. Let me know if this sounds similar to your situation. Also, the first thing to try is to move your Falcon2 closer to the outside vent. This will remove the distance question.

1 Like
8

Hello again. I apologize for the late reply.

I connected a Mixed Flow Duct Fan to a 4.7-inch pipe. It has the following specs: 31 dB, 27W, 2250 RPM, 167 CFM, and 90 Pascals of pressure. It was of almost no help. In fact, the machine’s own fan has better suction. I don’t want to install a larger fan, and I also don’t have the option to move the machine. I haven’t found a good solution for the smoke buildup. I just ventilate my house, and that’s all.

However, if I were to buy a fan again, I would try a centrifugal fan (blower/snail fan) of a similar size. Their Pascal value is much higher.

Also, cleaning the laser module was helpful. It delayed the time it took for my laser to overheat. Cutting at a low speed and low power was also beneficial. This is how I’m managing for now.