If you haven’t yet, try a cold pull and see if that helps. I personally just do a cold pull every time I change filaments. Maybe it helps, maybe it’s overkill, but I rarely have issues around clogs.
Other things to think about:
- Does this happen with other filaments? Maybe your current filament is wet and needs drying. Maybe you just got a bad batch.
- Does slowing down the print speed for infill make a difference? Perhaps this filament is just flowing differently and you need to change the printing temperature, flow rate, or just slow down.
- How old is your nozzle? They do wear out and a worn out nozzle can manifest as all kinds of wonky problems.
This just reminded me of an issue I was facing recently. I also use Prusa Slicer and was having a hell of a time with my prints. It turned out to be the “Arc Fitting” setting.
In Print Settings - Advanced - Slicing look for the *Arc Fitting setting. When I had it set to “Enabled: G2/3IJ” it just completely borked my prints. Just weird problems all over the place. As soon as I set that to “Disabled”, it cleaned up my prints considerably. Not sure exactly what I’m giving up there, but I do know I’m getting much better prints.