A design flaw in extruder sensor is causing filament loading and AMS errors

[fRAStone]

As can be seen in the image, those two corners or planes located at the entrance of the extruder—specifically at the filament sensor—cause the filament to hit them and fail to enter the extruder, returning back toward the AMS and causing numerous errors and failures. This happens especially when the upper part that holds the PTFE tube has play or is partially worn due to use. It would be highly advisable for BAMBULAB to modify the part so that the entrance is completely conical, which would completely prevent this issue. For this reason, it is also important to use some kind of PTFE tube aligner so that the filament is properly aligned with the opening and avoids these corners.

Maybe someone can design a printable replacement model until Bambu Lab fixes this issue

[GTX_Media_CoLab]

interesting, i notice i could influence that error from appearing by handling the ptfe tubes while the filament was loading. my intuition was always that this was from some sort of clogging, but it makes sense that it is from blockage. there is one ptfe guide design i have seen that I may try based on this insight, it was the next one on my list to print to solve this, but this proves it more, thanks!