MK4 print quality deteriorated recently?  

MK4 print quality deteriorated recently?

I'm hoping someone out there can help me or suggest anything to help.

I've had my MK4 for a year or more and been absolutely delighted by how it works and the print quality I have had using Prusament Galaxy Black PETG filament.

I have used it to print all the parts I designed for building into a Bear frame upgrade using parts from Prusa and E3d. The parts all printed and fitted well. The finished printer looks brilliant just like OEM!

However, being retired now I decided to upgrade the design by tidying up one or two areas and improve some aspects of the design to suit 3D printing better. When I print these parts now I get features on edges that I don't like and were not present on earlier prints - see the photos attached below.

If you lookat these photos you will see all the vertical edges have 'overun' anomolies where there should be sharp edges. I have modified some of the edges to have a small chamfer run along them to see if that helps; but the result is the same.

I am using the latest versions of Prusaslicer and Firmware, Prusament Galaxy Black PETG, Standard Prusa profiles so nozzle (0.4) temp 250C bed 80C/90C. I am printing with 4 perimeters and 5 top/bottom layers with Gyroid infill at 20%. All feeds etc are set by PrusaSlicer Prusament profile.

I checked all belt tensions are correct and cant find any looseness anywhere.

I have also printed the same parts with/without Input Shaping with very similar results. No matter what I try I just can't get the sharp edges I used to.

HELP!