Removing broken PVA from the Material Station


If filament breaks and/or gets stuck within the Ultimaker S5 or Material Station, this will prevent processes of the Ultimaker S5 Pro Bundle from functioning correctly. In these cases, an error code will be shown. The error code will indicate where the filament blockage was detected. 

This page contains step-by-step instructions on how to remove the broken material from the system. There is no need to disassemble the Pro Bundle or Material Station, apart from detaching a Bowden tube. Follow the link provided to get more troubleshooting information for the specific case or read the instructions below. 

Note: These instructions are also available as a PDF, which is found at the bottom of this page.

The following items are required:

  • Dummy filament (non-flexible and at least 2 meters)
  • Wire cutters / cutting pliers 
  • Flat-nosed pliers

Note: These troubleshooting steps apply to broken PVA, but the same steps can be taken if another type of material is stuck in the Material Station.



1. Note the error message and the affected bay
and extruder before switching off the Ultimaker


2. Remove the power cable from the Material Station


3. Open the Material Station. Check the system
for broken pieces of filament


4. Remove the spool of PVA from the Material

Note: The end of the PVA filament could still be stuck
in the prefeeder. Gently and carefully pull the filament out.


5. Remove the clamp clip and detach the Bowden
tube from the bottom of the Ultimaker S5 feeder
at the back of the printer

Note: Do not detach the Bowden tubes from the
decoupler. This risks damaging the tubes and it is
difficult to reinsert them properly.


6. Take another spool of filament and use the
wire cutters to cut a fine tip on the end of the

Note: Choose a non-flexible filament such as PLA or Tough PLA.



7. Make a double cut for a conical tip shape

Note: Avoid sharp edges; this may damage the
components inside the Material Station, such as the Bowden tubes.




8. Insert the filament into the Material Station
and apply force to manually push the material

Note: Sometimes, more force is needed than
expected. If it is not possible to push the material
through, try pushing from an adjacent bay. For
extruder 1, try the bay to the right. For extruder 2,
try the bay to the left.


9. Feed the filament all the way through the
system until all broken pieces are removed and
the new filament comes out of the Bowden tube
at the back


10. Cut the currently loaded filament at the
entry port of the Material Station

Note: Again, cut the filament at an angle and avoid sharp edges.


11. Grab the end of the filament sticking out of
the Bowden tube at the back and pull the
material completely through the system

Note: Use pliers to grab the Material, this will give a
better and firmer grip. It may take some force to pull
the material through.


12. Reattach the Bowden tube to the
Ultimaker S5 feeder and secure with a clamp
clip Insert the power cable into the Material
Station and switch on the Ultimaker S5 to
continue operation


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