@fcwilt What are the potential negatives to leaving the printer on 2.05?

@ziggymanpopo This is true. We rolled back the firmware from 3.3 down to 2.05 and the problem completely disappeared. Everything's working as it should now...what a very strange problem this has been, but I'm extremely happy to have a working printer now.

@secretasianman7 Interesting update: Just put a temperature probe from my meter under the silicone sock on the hotend and saw a consistent 20C temperature difference between what the duet reported vs what was on my meter. Throughout all temperature ranges tested, the meter reported 20C lower temperature than what was posted on the duet. This leads me to think I've got a thermistor issue of some sort. Any thoughts anyone? Where might I go from here?

@fcwilt Sounds like my next test will be to swap to 24V and see what happens then. Thank you for all your input.

EDIT: Upon second thought, I'd really like to avoid swapping to 24v if at all possible, because then I'm going to have to replace a lot of parts like my heater cartridge, bed heater and fans. Secondly, I've got a friend with a duet board printer he built thats 500x500, running 2amp steppers for his machine and he's on 12v running his machine without an issue. Also to add to that, once more, this machine worked perfectly in its original configuration on 12v before swapping to the duet board, so how could the origin on my problem be a voltage issue?

@fcwilt Alright, I just reverted to 3.3, heated to 215 and tried extruding into the air again, and its the same result. Skipping motor. I do notice that when I put my fingers on the filament and exert some downward pressure, I can get it to extrude with no skipping. I haven't made any changes to the config file since the last one I posted.

@fcwilt Thank you for all your thoughts and suggestions. To my knowledge, I am running a genuine duet board. It came from Matterhackers.

I don't mean to imply that there is something wrong with the duet boards, I wouldn't buy that myself. I simply feel that whatever problem I am experiencing with my setup originates with some sort of software misconfiguration or perhaps a mismatch of how my hardware was originally configured to run, vs how it is being run now. I am also very open to the idea that I have some sort of either firmware misconfiguration or poorly setup config file, as this is my first time doing anything with a 3d printer that isn't factory stock. I could have easily messed something up, or just have a lack of knowledge or understanding somewhere that is leading me to have this issue.

@fcwilt The stepper motor I started with was a Prusa LDO 018 stepper This model. The one I'm running currently is a creality 4240

Wiring on each is about 20-24 inches and it looks to be 24 gauge wire.

Here's why I dont believe it to be a stepper motor issue though. The machine I'm tweaking started its life as a Prusa Mk2S. The only hardware changes I've made to it thus far since installing a duet 2 wifi board have been the extruder stepper and an EZABL bed probe, instead of the PINDA the machine came with.

The machine functioned just fine before the board swap, and only developed these problems upon installing the duet 2 wifi. So with that in mind, how can it be a hardware problem when the same hardware functioned fine on a different board, right?

@jens55 Yes, sorry. No meaningful change has occurred yet. Here's what I've done since my last post.

• Took apart the hotend and checked for any sort of blockage. None could be found.
  Swapped nozzles again to a fresh 0.4mm.
  Double checked extruder motor wiring to make sure there was no loose connections. none found.
  Swapped heater block from 12v 30W heater to 12v 40W heater.
  Removed Filament feed gear from extruder and cleaned it thoroughly.
  Changed to another roll of PLA.
  Verified that my hotend fan was set to always on.
  Fed filament by hand through the hotend, no rough feeding was felt.

Unfortunately none of this has yielded any meaningful change and my extruder motor is still skipping when extruding into air or if attempting a print. Unless I'm still missing something, it seems like there's no hardware left to test and that this issue must be originating from something in the software somewhere, but I don't understand where. That's where I'm at right now.

@jens55 Thank you for your input. I do not have a voltage mismatch, as my board is being powered by a 12v PSU which came standard for my model of Prusa printer. I am using with it a 12V 30W E3D heater cartridge. I initiated a print just now, closely monitoring the temperature graph as the print went, and it stayed stable the whole time despite the extruder skipping. Temperature is not dipping upon start of print or upon turning on the part cooling fan. We are staying stable. I have not received any heater faults throughout my use of this board/printer combo, and if I request a print, it initiates. The only problem I am having is my extruder skipping when feeding filament whether extruding through DWC or upon printing.

@mikeabuilder If I recall correctly, Prusa switched to 24v with their MK3 system. I'm running a MK2S, which is running 12v. I know this because the bed level probe I'm using is 12v which I direct soldered to one of the the PSU output cables.

Now your question does make me wonder about my PSU and whether or not I'm providing enough current to my duet board. The PSU I'm using has 2 12v output leads. For the previous board which the duet is replacing, Both of those output leads fed into the board directly and then all the peripherals were powered off of that.

For the duet board, I took one of the 12v leads, tied it into Vin and took the other and used it to power my Z probe. Could it be that I'm not giving enough current to my board?