Solved Z Trouble

Then this is just a pure slicer issue.

The other stuff can be resolved after we get the slicer working correctly. But since this is MatterControl, the folks at MatterHackers may have a better idea of what is going on. Otherwise my suggestion is, first completely remove MatterControl and all it's settings, reboot your PC, download the latest version of MatterControl directly from MatterHackers.com (not from Robo). Reinstall and re-setup for the printer. After that you should be at a starting point. It is almost impossible to work on a system remotely where not all changes are clearly known.

The second suggestion would be to dump MatterControl completely and try one of the other free slicers such as Cura v 15.04.6 or Slic3r. The last suggestion is to dump all the free slicers and break down and purchase S3D.

 

These sort of problems (slicer ones) are why we eventually moved to S3D as well.
In every free slicer we ran into problems of some sort. Some where just annoying and others were fatal (as in there was no way to correctly slice some models). I just got tired of chasing them.

If the bulk of the models you print are precreated STLs then odds are good you can find a free slicer that will work if others have printed that model, but if the bulk of your printing is your own work it is just frustration.

 

You an open a bug with MatterHackers
you have a well defined test case it seems to me.

However if you want an immediate solution I think you need to try another slicer.

 

You can try the other free ones: Cura, Repetier host, Kslicer, etc.
MatterControl is not the only one out there.

I have tried every (unless there is a real recent one) free one out there (even host programs like pronterface) so if you need more ideas let me know.

edit: forgot skeinforge -- how I forgot that is a mystery because it was unforgettably difficult.

 

That succinctly summarizes my experiences with MC as well

 

Of all the free ones @mark tomlinson recommended, the only one I wouldn't use is KSlicer since development on it stopped a long time ago. Repetier-Host uses Cura-Engine or Slic3r if I recall and is really not a slicer per se, but rather a front end for a slicing engine. Engineering types usually like Slic3r since it gives you complete control over almost every aspect of the slicing process. S3D and MatterControl dumbs down most of the settings. The key differentiators of Simplify3D (S3D) is that you can take a deep dive into settings if you want to. They have put a lot of work into the actual slicing engine and while not perfect, it is by far the fastest slicer out there. One more thing, if you build your models and they must use supporting structures to print properly, the default settings of supports from S3D appear superior to any of the other slicers out there. Slic3r can be made to do what S3D does by default, but it takes a lot of trial and error. Meshmixer has as good a support structure as S3D but it adds another step to the workflow as it doesn't actually slice anything. The part that always makes me reluctant to make S3D a definitive choice is the cost of entry ($150 USD) and DRM (the anti-piracy methods used to make life harder for normal users as pirates will still pirate the software).

 

Yes you should be able to export the gcode from slicer to the sd card(i never used it, i went for simplify 3d)

The lcd controller is a great upgrade that takes communication issues out of the equation.

I still use the single 40mm fan for my electronics without issue, but most go for a larger to keep the electronics very cool.