So this time I did a manual Flow Dynamics and Flow Rate calibration. I then set it to the 0.16mm High Quality profile and left everything else default (including faster as Bullocks suggested).
On the plus side at least it fails a few layers sooner now.
Really strange. You should try to observe it in action, IRL, or if you have a recording. To me, it looks like it is emitting a bridge, which joins on the infill grid, but then cools and contracts UPWARDS so hard that the bridge tears out. It has to happen after the nozzle leaves, cuz the nozzle is literally in that space. If that’s actually whats happening you could force it to behave better by adding infill % to have smaller lengths between posts. maybe just in that area. Or maybe filament settings are what is causing it to be unruly.
It’s baffling and frustrating. I just put a new 0.4 hotend kit on it, did a factory reset and fresh calibration. Made no difference, still fails the same way.
2 days, 8 attempts, and 40g of wasted filament later, I give up. It’s just a simple box. I’m just printing it with 100% infill.