Just as an update in case anyone else comes across a similar issue - I haven't gotten it totally fixed but it seems to be related to my thermistor settings for my hotend. I was using a config that I found from CNC Kitchen (he swapped a Prusa to Duet) and I am using the same heater/thermistor so I assumed it would work fine. Once I found the datasheet for the thermistor and entered the values from there it seems to be a lot better. I am going through tweaking and PID tuning now but I am relatively confident that with some tuning I can make this defect disappear. Something to look for if you run into the same problem.

@mdbergholm and just to correct myself - the issue was NOT temperature related. My layer lines are super clean now that I have my hotend dialed in, but that was not what was causing my defect. I had M376 H5 set in the probe section of my config. I copied my config from CNC kitchen since I was using all the same hardware I was trying to make it easier for myself. In the end I went through line by line and culled anything I didn't deem necessary and verified on the duet wiki any line I didn't understand. Setting M376 H0 keeps mesh compensation on for the whole print and no more issue right at 5mm height...

Again...just in case anyone else runs into it. Check fade height. Thanks @gloomyandy for suggesting it.

Just as an update in case anyone else comes across a similar issue - I haven't gotten it totally fixed but it seems to be related to my thermistor settings for my hotend. I was using a config that I found from CNC Kitchen (he swapped a Prusa to Duet) and I am using the same heater/thermistor so I assumed it would work fine. Once I found the datasheet for the thermistor and entered the values from there it seems to be a lot better. I am going through tweaking and PID tuning now but I am relatively confident that with some tuning I can make this defect disappear. Something to look for if you run into the same problem.

@gloomyandy I am using mesh leveling with the inductive probe. I have not however set a fade height. Didn't know that was a thing. Will read up on it.

I do not have adaptive layers turned on. I am printing at 200um the whole time. The issue will happen on any part not just that one I've been printing could be a plain block. I have also printed this part on other machines without the issue showing up.

I can post up a sample of the gcode if it would be helpful. And I can def update all my firmware this is just how it arrived. I probably should get it all updated anyways.

;FLAVOR:RepRap
;TIME:10119
;Filament used: 7.59597m
;Layer height: 0.2
;MINX:97.941
;MINY:83.064
;MINZ:0.24
;MAXX:152.06
;MAXY:132.639
;MAXZ:49.64
;Exported with Cura-DuetRRF v1.2.9 plugin by Thomas Kriechbaumer
;Generated with Cura_SteamEngine 5.2.2
T0
M190 S70
M104 S250
M109 S250
M82 ;absolute extrusion mode
G28 ; home all
G29 S1 ; load mesh offset map
G92 Z0.3 ; z-offset
G1 X1 Y1 Z0.45 F10000 ; move to prime position
G92 E0 ; zero extruder
G1 X125 Y1 E20 F1000 ; prime nozzle
M83 ;relative extrusion mode
G1 F2400 E-0.55
;LAYER_COUNT:249
;LAYER:0
M107
G1 F720 Z0.44
G0 F9600 X99.382 Y89.896 Z0.44
;TYPE:SKIRT
G1 F720 Z0.24
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G1 X101.562 Y88.441 E0.02632
G1 X102.196 Y88.255 E0.0263
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G1 X104.052 Y131.8 E1.56076
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G1 X101.58 Y131.409 E0.02422
G1 X101.039 Y131.131 E0.02422
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G1 F2400 E-0.55
G1 F720 Z0.44
;MESH:bucket_sign.stl
G0 F9600 X120.491 Y99.045 Z0.44
;TYPE:WALL-INNER
G1 F720 Z0.24
G1 F2400 E0.55416
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G1 X121.169 Y98.89 E0.98699
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G0 F9600 X121.045 Y97.683
;TYPE:WALL-OUTER
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G1 X139.083 Y116.681 E0.02002
G1 X138.87 Y117.077 E0.0179
G1 X138.656 Y117.311 E0.01262

I had to keep cutting this shorter to get it to fit within a post... hopefully its enough to be useful. Note this is gcode with zero fan that still showed the issue. But even when running a fan I had it set to turn on at layer 2 to 15% and I watched it physically start on layer 2 as expected.

I am about to be travelling for two weeks so I appreciate all your suggestions and I will work on them when I return.

@mdbergholm and for anyone looking at this here is just a point of reference. My machine is basically the "Prusa Bear" upgrade frame with moons motors, and duet 3 electronics. Nothing out of the ordinary here. No crazy cooling or heating. All 12v.

@OwenD So on the left is 15% fan, on the right is 0% fan. The appear the same to me besides the lack of cooling causing some curling on the right side corners...and my bed offset....

and as for vase mode... Its hard to say I could have picked a better model to do this... but i think i see it there too.

@OwenD Yes - no issue with same hardware/print profiles using smoothieboard. I am currently printing a vase mode print to see if i notice a difference there. After that I will try the other part again using 0 fan. With the prints you saw I am using only 15% fan speed.

@mdbergholm

Here is my config.g

; ##### General preferences
G90                                          						; send absolute coordinates...
M83                                          						; ...but relative extruder moves
M550 P"Rob"                          								; set printer name

; ##### Network
M552 S1                                      						; enable network
M586 P0 S1                                   						; enable HTTP
M586 P1 S0                                  						; disable FTP
M586 P2 S0                                   						; disable Telnet

; ##### 12864 Menu
M918 P2 E-4

; ##### Drives
M569 P1 S0 D3 V10                                					; X drive @1
M569 P2 S1 D3 V10                                					; Y drive @2
M569 P0 S1 D3 V100                               					; Z left drive @0
M569 P4 S0 D3 V100                               					; Z right drive  @4
M569 P3 S0 D3 V0                                					; E drive @3 - inversed
M584 X1 Y2 Z0:4 E3                     								; set drive mapping
M671 X-37:287 Y0:0 S10                                     			; define dual driven z-axis 

M92 X160.80 Y159.60 Z388.16 E140.00             					; set steps per mm
M350 X256 Y256 Z256 E256 I1                      					; configure microstepping with interpolation
M566 X600.00 Y600.00 Z48.00 E300.00        							; set maximum instantaneous speed changes (mm/min)
M203 X8000.00 Y8000.00 Z720.00 E7200.00      						; set maximum speeds (mm/min)
M201 X1250.00 Y1250.00 Z1250.00 E2000.00        					; set accelerations (mm/s^2)
M906 X1000 Y1000 Z1000 E1200 I30                					; set motor currents (mA) and motor idle factor in per cent
M84 S30                                      						; Set idle timeout

; ##### Axis Limits
M208 X0 Y-4 Z0 S1                             						; set axis minima
M208 X255 Y212.5 Z215 S0                       						; set axis maxima

; ##### Endstops
M574 X1 S1 P"io0.in"                        						; X endstop
M574 Y1 S1 P"io1.in"                        						; Y endstop

; ##### Z-Probe Settings for PINDA 2
M558 P5 C"io2.in" I1 H1 F1000 T6000 A3              				; Prusa PindaV2 Endstop
M574 Z1 S2                                                 			; Set Z axis endstop, controlled by probe
M557 X0:220 Y0:205 P5                                    			; Define mesh grid for probing
M376 H5																; Fade height 5mm

; ##### Heaters
; Bed Heater
M308 S0 P"temp0" Y"thermistor" B4725 C7.060000e-8 					; configure sensor 0 as thermistor on pin temp1
M950 H0 C"out0" Q25 T0                           					; create bed heater output on out0 and map it to sensor 0, PWM frequency: 25Hz
M307 H0 R0.262 C338.0 D10.52 S1.00 V11.8 B0							; Bed tuning values, enable PID
M140 H0                                                    			; Bed uses Heater 0
M143 H0 S120                                               			; Set temperature limit for heater 0 to 120C Bed
; Hotend heater
M308 S1 P"temp2" Y"thermistor" T100000 B4092 ; configure sensor 1 as thermistor on pin temp1
M950 H1 C"out2" T1                           ; create nozzle heater output on out1 and map it to sensor 1
M307 H1 B0 S1.00                             ; disable bang-bang mode for heater  and set PWM limit
M143 H1 S275                                 ; set temperature limit for heater 1 to 275C

; ##### Fans
; Part cooling fan
M950 F0 C"out3" Q100                         						; create fan 0 on pin out3 and set its frequency
M106 P0 S0 H-1                               						; set fan 0 value. Thermostatic control is turned off

; ##### Tools
M563 P0 D0 H1 F0                             						; define tool 0
G10 P0 X0 Y0 Z0                              						; set tool 0 axis offsets
G10 P0 R0 S0                                 						; set initial tool 0 active and standby temperatures to 0C
M572 D0 S0.06								 						; Pressure Advance

; ##### Startup
M18 XYE                                                				; release / unlock X, Y, and E axis
M501                                                   				; use config-override (for Thermistor Parameters and other settings)
G90                                                    				; send absolute coordinates...
M83                                                   				; ... but relative extruder moves

@OwenD I count about 25 layers on both 70c bed and 40c bed. That was my first thought was the bed was too hot. I updated my initial post with details on printer and software. Seems like a simple issue TBH just strange.

@OwenD Sorry I meant to also post that I lowered my bed temps to 40c (from 70c) because any lower it wouldnt stick to the bed at all. When doing this i seemed to get quite similar results

The silence is incredible, but I am running into a strange issue that I am a bit perplexed with. I ran PID tuning for both hotend and bed, but still getting a strange defect where the first 25 layers or so are printing slower? or hotter? than the rest? They seem to have more shine and shrink slightly more indicating more heat. I have tried creating a brand new profile using Cura and Prusaslicer and to my surprise got the same result.

The hardware is basically a Prusa MK2.5 with all extruded aluminum, and Duet 3 Mini 5x

Duet Web Control 3.4.5
RRF 3.4.0
Duet Wifi Server 1.26