I have a dual extruder Prusa with MK8 heads and direct drive steppers.

My prints are beautiful until they just stop extruding and i find my nozzle going to town floating layers above the print being no productive. This often happens many layers and an hour+ into the print.

Ive played with the tension and temp for hours. I even went so far as to very gently file one of the driver gears down a little so it wasn't so sharp. I've slowed the overall rate to 65%.

The extruder steps are calibrated and accurate to within 1mm in 100mm.

Same outcome. Prints great until it just quits producing filament and i find a ground down section in the mechanism. Any lighter tension and it wont pull.

Do you guys have any ideas?

Thanks gents,

Zan