Filament fails to feed after ~45 minutes consistently.  

Filament fails to feed after ~45 minutes consistently.

I've got a relatively new Prusa Core One Plus unit (few weeks old). Since setup, I've not been able to get consistent performance out of the printer. The symptoms look something like the following:

1. I start a print that should take roughly an hour, to an hour and five minutes. 
2. Within 20-30 minutes a clicking noise begins from the idler/planetary gearbox and extruder motor. Filament fails to feed through anymore.
3. The print continues but is just printing on "air". I typically need to intervene at this point and abort the print because it doesn't detect the feeding problem. 
4. I cannot pull the filament out. I have to unlatch the filament PTFE tube, cut the filament, and then disassemble and remove the nozzle. 
   1. (just unlock the idler and pull it out -> not possible, it's like solidified in the nozzle). 
5. Finally, I have to use a heatgun to heat the nozzle up and "cold pull" the filament. 

This has happened across several different nozzles, and different filaments (though all PLA). I'm running out of ideas as to what the cause could be, and am beginning to tire of constantly disassembling the top to unjam the printer just to have it fail again an hour later. I'll contact support after the weekend but am hoping I can get some ideas from the more experienced users here in the meantime 🙂

FAQ

• Your filament is probably saturated due to humidity. Try drying it first: I unwrapped a fresh filament reel and had the same problem happen just now. So the filament condition seems to not be a factor
• Your nozzle needs to be cleaned, or your nozzle settings are wrong: I've had this problem with both the 0.4 brass high-flow nozzle, and a 0.4 hardened nozzle. I've swapped between them multiple times now and consistently experience the same problem. When running the high-flow brass nozzle, I set Settings > Hardware > Printhead > {Nozzle Hardened = OFF; Nozzle High-flow: ON}. When running the hardened nozzle, I set { Nozzle Hardened: ON, and Nozzle High Flow: OFF }.
• Where did you get your nozzles?: Both came from Prusa
• What filament are you using?
  • Type: Prusament PLA Vanilla White
  • Nozzle temperature (per box label): 205-225C
  • Headed temperature (per box label): 40-60C
  • Tolerance: 1.75 +/- 0.012mm
• Your slicer / print settings are probably wrong: Could be. Here's what I'm setting:
  • Slicer Settings (Beginner mode in PrusaSlicer):
    • Filament: Prusa PLA
    • Printer: Prusa Core One HF0.4 nozzle (when using the brass nozzle), else Prusa Core One 0.4 nozzle (when using hardened) 
    • Filaments:
      • Diameter: 1.75mm
      • Density: 1.24 g/cm^2
      • Idle Temperature: 170C
      • Nozzle (first layer): 230C
      • Nozzle (other layers): 225C
      • Bed (first layer): 60C
      • Bed (other layers): 60C