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Boxzy Milling Making Strange Noise and Eratic Milling

I was in the middle of making a jig and just at random the head starts following it’s own eratic movements. I was cutting simple circle pockets and the machine just starts cutting odd paths. The Z motion is acting up as well, instead of smooth movement you can hear and see it moving in steps instead of smooth motions. The Z movement also changes, meaning it moves lower than entered into the Gcode. There seems to be 2 points on the Z down where it sounds it struggles to get past 2 different parts.

Also, the Boxzy started to make a strange noise while sitting Idle, like a tapping thud noise. It’s not continuous, but every 5-10 seconds. It sounds like it’s coming from the back of the machine.

I reset by removing power and the USB and relaunching the app, I also created a new file on Easel and the problem still happens. All the limit switches are clean. Any suggestions?

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What you are describing is overheating drivers exactly. It was a flawless description of that issue, including the idle noises and erratic movements. Please check to verify that your back fans are working, the mesh filter is clean, and your circuit board is not covered in dust.

I'm confident the issue is a failing fan, clogged/blocked filter, or both. Both fans are 100% necessary.

Note: you should avoid cutting particle board directly without using a vacuum to immediately capture the dust. The dust is so fine and basically microscopic that it gets onto and clogs everything. It can also find its way into the bearings too easily. If you milled a significant amount of particle board without a vacuum, you will need to lubricate your bearings and ballscrews as soon as possible. The particle board dust dries the bearings and ballscrews out almost immeidately. You will also need to thoroughly clean your back electronic cover, boards, fans, and mesh filter.

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Before I received the email notification I was checking the rear of the Boxzy and noticed I didn’t hear the fans spinning. It was exactly what you said, the fans weren’t working. You must have some sort of Voodoo Vision :)

I ordered 2 new fans as both were seized. I have no idea why, but I cleaned everything while I had the cover off. So in theory, with the new fans in place when they arrive everything should return to the norm.

I would also like to say thank you for the quick response and guidance.

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Glenn Auer will be eternally grateful.
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