This is a follow up from my spaghetti post a few days ago.
Good news: I caught the nozzle catching on the infill during travels. The infill must have been curling up ever so slightly. Turning z-hop on solved this. I also bumped my nozzle to 255 based on a temp tower, but I don't think my original issue was flow related.
Bad news: this brought me to the failure above - evidently my chamber temps are too low for this size of ASA part and it warped. Maybe the higher nozzle temp contributed. Maybe this size of ASA part is unrealistic despite not having sharp corners. Maybe it's the fact that it's continuous from side to side. I am still going to attempt to print a hollow cylinder to go between this piece and another similar piece in ASA, so I guess we'll find out!
Good news: the part did not let go of the build plate. I'm pretty happy about this. My first layer is not overly squished, I've never used any adhesion aids (glue stick, hair spray, ASA slurry, etc), etc. Tuning my print_start sequence is resulting in a very consistent first layer.
Bad news: the build plate came up with the print. Holding the build plate down with binder clips or the like would probably just make something else fail.
Good news: I had enough PETG in stock to use that instead. Zero warpage, so great success. I had to go a bit slower because a flow test showed that I'm limited to around 25 mm^3 for PETG before the extrude motor started misstepping, despite bumping temp to 255 °C. I limited flow to 20 mm^3 to be safe. The print's a success so meh.
If you cant increase chamber temp, you can try reducing bed temperature. There is a minimum bed temp you need fot first layer, but you can try dropping it even more (5C) after a layer or two. PEI shouldnt loose adhesion and you will have a bit less shrinking. Not sure would that be enough for your part tho, warping is massive
Do you think this is something I could combat with higher chamber temps? I've been putting off swapping my acrylic panels for ACM and installing radiant insulation, but if it will help...
Using my hot end thermometer as a chamber thermocouple (hot end fan on high), 75mm above the bed and in the centerish it looks like I'm hitting around 50 °C after 45 minutes or so. I doubt it's getting much hotter in there.
My bed is already fairly low at 100 °C, but I could try 95 °C after the first layer as you said. I can also lower my extruder temp some, but ambient is still going to be way cooler than the plastic coming out of the hot end.
Higher chamber temp should help and I think its the best way to deal with this issue. If you are going to try a different build surface like Kapton, consider gluing PEI sheet directly on the alu plate instead (not the spring steel sheet, just a PEI)