Thank you for your helpful reply!
"A FFF-Profil doesn't replace a FACTORY-File!
A factory contains also the STL of the model and this is needed to find out the reason."
I have read that the S3D Terms of Service prohibit publicly posting Factory Files, and that specific queries of S3D on this issue were not definitively resolved. Did I misunderstand what I read, or was it just inaccurate?
Can you shed any light on this matter?
"Nevertheless try out to set INFILL >>> Minimum Infill Length down to zero (now 1 mm)."
We tried from 5mm down to 2 then to the 1 reflected in our Profile with no visible improvement. I'll go take that further step now and report back here. Thanks for motivating me
"You are using version 4.01. If I remember right, this version was a little bit faulty and was replaced by version 4.1 and now we have 4.1.2 (and hopefully waiting to version 5
Our Machine Specifications text was incorrect - the tests were all made using S3d V4.1.2
Again, thanks for your courteous and helpful response!