I'm stumped!! I've printed about 5 of the same thing sliced with different settings in slic3r but couldn't get a usable print.
the first 2 layers always prints beautifully, but after the third the problems start appearing and just gets compounded as it goes. it looks like blobs starts forming at the nozzle and as it prints, the blobs get caught onto the print and start building up bigger and bigger. see attached image.
Printing on Mendel w/ Gen6/Sprinter, 3 mm PLA filament, mendel-parts v6 style hot end w/ 0.5mm nozzle
Sliced with slic3r 0.7.1, settings as follows
Layer height - 0.4 mm
Fill density - 0.2
Fill angle - 45
Fill pattern - line
Solid fill pattern - rectilinear
Nozzle diameter - 0.5 mm
Filament diameter - 3.0 mm
Extrusion multiplier - 1
Temperature - 160 C
First layer temperature - 170 C
Print speed
Perimeter - 24 mm/s
Small perimeters - 24 mm/s
Infill - 48 mm/s
Solid infill - 48 mm/s
Bridges - 60 mm/s
Travel speed 64 mm/s
Bottom layer speed ratio - 0.3
for extrusion width (ratio over layer height) I've tried 0 (auto) and a calculated value based on measurements from a piece of extrusion, result being 1.157894737... but there was no noticeable improvement.