I am saddened to see that this thread had no mention of how many horses it takes to run a router. What do y’all think? Would one be enough? It would need to work in shifts to keep up time at 100%. Maybe 3 to be safe?

This thread went unexpected places. I can’t even imagine the pain. I hope you keep printing little bits of joy for them.

This looks similar to a problem I was having. Turned out that my extruder wasn’t calibrated properly and it was pushing far less material then expected. Try running an extrusion test like described in https://ellis3dp.com/Print-Tuning-Guide/articles/extruder_calibration.html

The future is already here – it's just not evenly distributed.

The Economist, December 4, 2003, William Gibson

I think about it like the tires on a car. They are (hopefully) the only part of the car that touches the road. If they aren’t working correctly everything else isn’t going to save you from a gentle curve in the road.