PRUSA XL Filament stuck when printing PLA  

PRUSA XL Filament stuck when printing PLA

Hi all,

The issue: when running long (>6 hrs) prints using PRUSAMENT PLA the printer will stop detecting that the filament is stuck. This seems to happen every time there are small features to be printed (for example the end of organic supports). 

I have been having this issue since we received our PRUSA XL. Initially I thought it was one extruder that was defective, but the issue seems to be present on all extruders. I also thought it was the chamber getting too hot, but even with the door open the problem persists.

I don't seem to have this issue with PETG.

The fix: unlaod and reload the filament. When unloading I notice a bulge at the end of the filament, sometimes this bulge makes the filament hard to remove from the toolhead (had to remove the PTFE tube and pull the filament from the top). Could it be over-extrusion?

In the slicer I have used the standard presets for filament and print, nothing changed. So far only printed with 0.4 mm nozzle using 0.2 mm layers.

Printer firmware is 2.6.2 (as received). The printer is barely 1 month old, did not print much on it. All the calibrations and tests were fine, belt tension is fine and filaments are new and dry. Nozzles are the stock ones, as-received fomr the factory. I have added the silicone socks to the heatblock.

Any ideas? Thanks for your help!