Problem with Wifi module affecting prints

Flagship K Series Creality Flagship K1 Max
1

I am noticing a consistent issue that I’m not sure exactly how it’s triggered, but it points to the Wi-Fi module being the issue and causing problems. Even if you’re not using the Wi-Fi, it still causes the issue.

The issue:
The symptom:

  1. Prints fine on first boot. After a few prints (could be a second print) it looks wrong. For example, the first layers off, retraction is bad, and z can also be affected creating thin print lines.

  2. Reboot, then send the same file from orca (without change), and it prints fine again.

  3. When it’s going into this weird mode where it’s printing poorly, going into fluid and adjusting the flow, z offset, or any calibration setting seems to have 0 affect. Reboot, send print is the only way it’s fixed and starts to print right again. Basically all settings from your slicer appear to be ignored, and the print is using some “generic” or default values from the printer.cfg file, I assume.

  4. I have been monitoring hardware stats and usage on my 3d printer, but I’m not seeing a starved resource. It’s unclear what the problem is, where it’s coming from and why it is happening on multiple k1 max as I’ve seen this happen on all 3 that I own.

    Diagnosis:
    #### 1. Recent Kernel Messages - Wi-Fi Errors Present

dmesg | tail -20

**Results:**

4896.589130] CFG80211-ERROR) wl_cfg80211_get_station : NOT assoc
[ 5648.801579] start st7701 init.
[ 6286.633391] CFG80211-ERROR) wl_cfg80211_get_station : NOT assoc
[ 7546.609316] IRQ Error, cpu: 0 Cause:0x08800000, Status:0x14001c00
[ 9741.439480] CFG80211-ERROR) wl_cfg80211_get_station : NOT assoc
[32000.058710] IRQ Error, cpu: 1 Cause:0x08800000, Status:0x14001c00
[38164.634455] IRQ Error, cpu: 0 Cause:0x08800000, Status:0x34001c00
[43270.170600] CFG80211-ERROR) wl_cfg80211_get_station : NOT assoc

**Key Findings:**

- CFG80211-ERROR messages (Wi-Fi driver errors)

- IRQ Error messages on both CPU cores

- SPI activity (st7701 display controller)

#### 2. Recent Klipper BlockingIOError - FOUND ACTIVE ISSUE

dmesg | tail -20

**Results:**

[ERROR] 2025-09-06 09:58:32,247 [root] [gcode:_respond_raw:551] Write g-code response
BlockingIOError: [Errno 11] Resource temporarily unavailable

**CRITICAL FINDING:** BlockingIOError occurred TODAY at 09:58:32 during g-code response write - this is exactly what causes Fluidd unresponsiveness!

#### 3. Wi-Fi Processes Running (Despite Not Using Wi-Fi)

ps aux | grep -E ‘wifi|wpa’

**Results:**

1364 root 1:24 wpa_supplicant -B -i wlan0 -c /usr/data/wpa_supplicant.conf
1536 root 1:00 /usr/bin/wifi-server

#### 4. Wi-Fi Driver Module Loaded

lsmod | grep cywdhd

**Results:**

cywdhd 928299 0
soc_msc 24756 1 cywdhd
soc_utils 2123 1 cywdhd,[permanent]
utils 15573 19 [multiple dependencies including cywdhd]

**FINDING:** The problematic cywdhd Wi-Fi driver is loaded and active

#### 5. Network Interface Status

ifconfig -a

**Results:**

- eth0: Connected at 10.1.1.94 (working fine)

- wlan0: Present but not connected (0 RX bytes, some TX activity)

I have disabled the Wi-Fi and noticed instantly the printer starts to behave properly again. Though, the next time you reboot, the Wi-Fi is re-enabled. I can only assume this is a driver or hardware issue, but the fact I’m seeing this on 3 K1 Max, and the same behaviour, makes me think this is more of a driver issue.

2

The wireless seems to be a false positive, and potentially harmless.

root@K1Max-6475 /root [#] echo "3. Checking for any BlockingIOError in current logs:" && tail -50 /usr/data/printer_data/logs/klippy.log | grep
-E "BlockingIOError|Resource temporarily unavailable" || echo "No BlockingIOError found" && echo "4. Current CFG80211 error pattern analysis:" &
& echo "Errors since boot:" && dmesg | grep "CFG80211-ERROR" | wc -l && echo "Latest pattern:" && dmesg | grep "CFG80211-ERROR" | tail -3
3. Checking for any BlockingIOError in current logs:
No BlockingIOError found
4. Current CFG80211 error pattern analysis:
Errors since boot:
14
Latest pattern:
[42893.613531] CFG80211-ERROR) wl_cfg80211_get_station : NOT assoc
[44011.088652] CFG80211-ERROR) wl_cfg80211_get_station : NOT assoc
[50227.127432] CFG80211-ERROR) wl_cfg80211_get_station : NOT assoc

I have however changed my Wifi to point to AU instead of GB since i am in Australia though i dont think it will make any changes to the error itself:

sed -i 's/country=GB/country=AU/' /usr/data/wpa_supplicant.conf

I will continue to monitor for the BlockingIOError

BlockingIOError: [Errno 11] Resource temporarily unavailable

but as I mentioned, I have not worked out how to replicate it.

3

My original diagnoses was leading me to a Wi-Fi issue, but I have managed to track the problem I was experiencing to a debug enabled log file, causing all sorts of problems. I have created a new page with my diagnoses here: K1 Max Memory Exhaustion Issue