Why are my chicks having trouble at hatch

I'm pretty sure there's no such thing as chickens getting too big inside the shell. They'll grow slower at lower temperatures, yes, but that also delays the hatch date. It slows everything down, not just their growth. Chickens develop and grow until they're ready to hatch, then they hatch. They aren't going to grow too big while still in the embryo stage.
You need to keep the humidity up or they dry out and can't hatch. Raise the humidity and keep it up.
 
I agree with Fishkeeper on temp, if you lower it under 99.5* you are just going to trade one problem for another. However, if you run high humidity levels during incubation the eggs don't lose enough moisture. This often leads to chicks that die in the shell at or near hatch time.
 
No I know they don’t need calibration. I have 2 sets and there both right with in .5* at the most on temp and .5% in humidity. BUT i will check it again in a few days when these come out of the incubator
 
Have you tested your hygrometer for accuracy? Everyone usually has a different opinion on humidity, but I run mine around 30% for incubation and 60-65% during lockdown and this works for me.
So if I wanted to leave my Humidity at the same level throughout incubation what would you suggest it be set at? The reason I am asking is because I often add eggs throughout incubation as I collect them. I Sometimes collect a weeks worth of eggs then put them in the incubator and then wait another week to collect more and put them in
 
So if I wanted to leave my Humidity at the same level throughout incubation what would you suggest it be set at? The reason I am asking is because I often add eggs throughout incubation as I collect them. I Sometimes collect a weeks worth of eggs then put them in the incubator and then wait another week to collect more and put them in
This, actually may be the root of your problem. Staggered hatches can be very problematic because of the necessity for raising the humidity so much during lockdown and hatch. This causes the remaining eggs to be unable to lose the correct amount of moisture to allow them to hatch well. The remaining eggs are also subjected to the hatched chicks pushing them around, often quite violently.

Eggs that are unable to lose the correct amount of humidity often have enlarged chicks because the air cell does not expand correctly. This also causes difficult hatches.

If possible, I would try to plan your incubation all at once. Collect you eggs and store them cool and quiet for a week and then incubate them all at the same time. I think your hatch rate will increase.
 

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