Very inconsistent first layer causing adhesions issues, nozzle contact with part, layer shifts, and rough top layers.  

Very inconsistent first layer causing adhesions issues, nozzle contact with part, layer shifts, and rough top layers.

Hello,

Been running the Prusa Mini+ for a couple years now and have started to run into some issues. I am on the latest firmware with Input Shaping using prusament pla and the associated profile in prusa slicer (.2 structural speed)

1. I can hear the nozzle contacting the print.

2. Very rough top surface finishes as a result of nozzle contact.

3. Sometimes the nozzle will hit hard enough to cause a layer shift by physically moving the spring steel plate.

4. Very inconsistent first layer is probably the root issue but i have been unable to tune it on the calibration. see photos lines change width throughout the calibration print. ALL OF THE LINES IN THE PHOTO WERE TAKEN WITH THE SAME Z OFFSET. I did not change the offset mid calibration.

Trying to figure out whats going on with the printer.
Perhaps the pinda is failling? That could explain why the first layer is so inconsistent. But i do see the z stepper moving up and down during the calibration print.

Maybe the IS firmware itself is causing inconsistent extrusion thus pushing too much or too little plastic? Perhaps i should roll back to an earlier firmware without IS?

Any other thoughts?

Thanks.