Thank you Afinia support! We got our print head back from Afinia at the beginning of this week and she is up and running again. The repair folks couldn't find anything really wrong with it but they gave us a new heating element and extruder tip.
The repair process was quite painless. We notified Afinia of the problem, they offered several tips to correct it but none of them worked. A day or so later they generated an RMA number for shipment of the part to them and off it went. We were asked to provide samples of the filament that was not feeding into the extruder which we did. They wanted to test the part under similar conditions in order to replicate our issues as closely as possible.
Somehow, my email address got jumbled and a request by Afinia support for more filament didn't reach me. So, they just shipped the extruder back with the new parts and we are back on track. We still don't know exactly what was wrong with the thing but if constant use has anything at all to do with it then there's your culprit.
Once again, thank you Afinia for addressing our problems quickly and with professionalism. We are extremely happy to be back and printing again!
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