I’m sorry for the trouble with your filter, and for the frustration.
When your Glowforge and Compact Filter are properly set up, you may have some harmless odor during printing which will rapidly dissipate. You may also smell something when you open the Glowforge lid after a print is complete. This is not harmful.
However, if you notice a strong, unpleasant or irritating odor when printing, or see smoke, shut off your Glowforge unit immediately. Smoke and fumes could be entering the room in excessive concentrations.
Thank you for the information that you’ve already tried some of the troubleshooting steps. https://glowforge.com/support/topic/troubleshooting/print#excessive-smoke-or-fumes-during-print
Would you please let us know which steps you haven’t done as they weren’t feasible?
To help troubleshoot your exhaust, could you send me a few photos of your exhaust system? Specifically, please include pictures of the following:
The exhaust fan from the inside of the unit. To capture this photo:
Turn your Glowforge off
Open the lid
Using both hands, gently pull the printer arm towards you as shown below:
Move your phone or camera inside the Glowforge on the left-hand side, past the metal rail, pointed away from you towards the exhaust hose, to capture a photo like the one below:
A photo of where your exhaust hose attaches to the Glowforge, where your exhaust hose exits the room, and the path your exhaust hose takes from your Glowforge to the exterior vent or Compact Filter
The exhaust connection on the back of your Glowforge, with the exhaust hose removed:
After taking photos of the above, please also include a photo of you Compact Filter cartridge:
Turn off and unplug your Compact Filter
The power switch is located on the back, next to the cord. Turn it off first, then unplug it from the wall.
Open Compact Filter
There are four latches holding the top of the Compact Filter in place. Lift the bottom of all four latches to release them.
Take a picture
Without removing it, take a picture of the top of the cartridge seated in the Compact Filter and send it in to us.
We’ll review the images and follow up with next steps. Thank you!