This is a part I’ve printed at least 50 times without issue. Recently I’ve been getting the circled pattern in the exact same place. I’m using 3D Fuel PLA+ which up until recently has never had an issue like this.
The orange part was printed with the latest firmware and latest bambu studio on a P1P.
The white part was printed on a different P1P with the firmware rolled back twice and bambu studio rolled back twice.
The .3mf files are for two different parts with identical geometry in the highlighted area. I currently have 6 parts with the same problem printed in various combinations of firmware and software setups.
I have also gone back to the original CAD model and exported a new 3mf with same results as above.
Welcome to the forum.
Regarding your question, you stated many variables.
I can imagine that for you, it may be straightforward, as you´re doing the work and know the details; however, for me:
two different printers (even if the same mode);
different filament (at least colour);
different software and firmware;
You may be right in assuming it is the software and firmware, but the difference can be attributed to any of the above variables.
From what I understand, you assess the effect of firmware and software, which are shown in the figures. Regarding the software, are these differences noticeable in the preview pane? It would be great to see the effect of the software and firmware (one at a time) in the same printer with the same spool.