A few updates. First, my PETG is always kept dry. Always stored in air tight containers and dried before use (8 hrs @ 60). I did switch to Arachne wall generation. But this was my first use of Arachne and getting settings dialed in is somewhat difficult. I used ChatGPT to help me better understand the terminology and give me some starting values and after several shots I think I got it dialed in fairly well. ChatGPT is really nice since you can upload an image of your issue and it analyzes and gives you recommendations. Granted it did a lot of hallucinations but with guidance I think it did a reasonable job. Here are my Arachne settings:
Wall transitioning threshold Angle: 5
Wall transitioning filter margin: 30%
Wall transition length: 50%
Wall distribution count: 3
Minimum wall width: 60%
Minimum feature size: 15%
Yellow is printed first. I also made a series of changes to the Process profile including reducing Outer & Inner Wall Line width to 0.35 mm, slowing inner & outer wall speed for the first few layers, reducing acceleration (but not as much as suggested), etc…
Trying to complete the print and will post an image of the results once available. It’s not perfect but better.