This is printing PETG extruding at 250 °C, 1st layer bed at 80 °C then 60 °C on other layers. Nozzle is 0.4 mm; printer is German Reprap X400. The all metal extruder is clean with no oozing. The print gets a blob when the wall width changes from 2 mm to 1 mm. The extruder squishes the blob out the sides of the wall with subsequent layers. Images below show both sides of wall. I'm looking for the cause to come up with a fix. I consistently get the same results in the same location when printing this file. The reduced area of the layer does cause reduced speed to increase the print time for the layer (speed reduced when layer would print in less than 30 seconds; minimum speed 15 mm/s).
When I printed two, there was only one blob on one of two. Below shows the speed settings. The perimeters are three vertical shells, so the walls are all perimeters. My understanding of the setting is the 2 mm wall printed at 20 mm/s and the 1 mm wall at 15 mm/s.
Printing similarly with 2 mm walls only and the same settings, the print is nearly perfect with only a few stringers. Printing with only 1 mm walls does not have the blob, but does have stringers.
See solution at the end.
Speeding up the print speeds and using thicker walls not only eliminated the blogs, but also completely eliminated stringers, and gave a near perfect print. Apparently, the actual temperature that PETG extrudes is highly dependent on how fast it extrudes. Printing too fast clogs the nozzle because the filament doesn't have time to melt. Printing too slow causes the hotend to stop extruding from heat creep. Here, the actual temperature of the extruded PETG was decreased by speeding up the extrusion.