When you say same print file, I assume you mean the same gcode, same printer physical location, etc?
Is it consistent and repeatable? For example, what happens if you print the same file back to back?
this post was submitted on 17 Sep 2023
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Yes to everything in the first sentence. It’s not consistent, maybe 1 in three come out perfect, then the others turn out badly.
Does your nozzle touch your endstop or does something else? I wonder if you're having an inconsistent first layer. That can mess up my top layer and it wouldn't surprise me if it also impacted overhangs.
I’ve not had any first layer issues, all have had good extrusion and adhesion. Nothing appears to be touching.
On my Voron my nozzle triggers my z endstop. I've noticed that if I have gunk on the nozzle from the last print I won't consistently z home. That can lead to all kinds of interesting print inconsistencies.
That’s interesting, thank you, I’ll double check that too.
Looks like a weird extrusion issue, is your ender 3 completely stock?
It has a Bigtreetech SKR mini E3 V3, but stock otherwise.
Have you checked the extruder arm? They tend to crack. Although this looks more like overextruding rather than under, which you would expect if the arm was cracked. Still worth to check it out though