3DPrinting
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Super bizarre...
Any chance there's some mechanical damage to the thermistor? If you've rebuilt the hotend a bunch of times it's really easy to do, I've totally reefed down on a setscrew before and flattened one, could lead to it possibly reporting a wrong value, a crack + high vibrations during printing + thermal cycling could lead to it getting worse over time. Sudden shifts to me would suggest a problem with the thermistor itself, especially given the total overhaul you've done. As crappy as it is too, if I recall electrical components often follow an early failure pattern where they can have a higher failure rate at beginning of life and then drops off, for the price of thermistor cartridges it's not a bad idea to keep some on hand just in case.
To make your life easier, Do you have a molex connector at the hotend? A lot of thermistor cartridges come with short leads and a molex connector, makes swapping them so much easier. If you don't already have some crimpers, Engineer PA-09 is a solid pair that'll do everything from molex to jst.
Thermistor swap was done a few times on the old board when the same issue was happening. I had 3 of them that I was swapping between.
Currently in there is a pretty nice thermistor that, rather than using a set screen to keep it in place, is actually built in to the end of a set screw; it's effectively impossible to damage it. Unfortunately, it's a known-good resistor, my problem lies elsewhere.
Wow yeah, that's even more annoying then. Last ditch thing to me would be to check the resistance across th0 and compare to thb, I got ~6.28 kohms on both checking a spare board, just super strange this happened so suddenly.
Good call on checking that resistance, didn't think of that before.
Even more frustrating is it happening twice across two different boards!