What is the most common cause of premature belt failure in an FDM printer?

The most common cause of premature belt failure in an FDM (Fused Deposition Modeling) printer is improper tension. Belts are used to transmit motion from the stepper motors to the print head and bed. If the belt is too loose, it will slip, leading to inaccurate movements, ghosting in prints, and ultimately, wear on the belt as the teeth skip. If the belt is too tight, it puts excessive strain on the belt material, as well as the motor and bearings, accelerating wear and potentially causing the belt to stretch or snap prematurely. Incorrect alignment of the pulleys and excessive debris accumulation are also contributing factors, but incorrect tension is the most frequent reason for early belt failure. Regularly checking and adjusting the belt tension according to the printer manufacturer's specifications is essential for maximizing belt life and maintaining print quality.