Had Esab and Bohler 1.0mm wire, plenty reels in the past, no problems. Put a new 18kg roll of Esab wire onto the Miller a couple of weeks ago after finishing a reel of Bohler, and instantly started feeding badly. The wire seemed to snatch in the tip like it was overheating. Out of interest, measured a bit of Bohler wire, and a bit of the new Esab... the Esab is 0.988mm and the bohler was 0.972mm (estimating the last digit and averaging the readings) The esab wire is perfectly round, too. Anyway, we were just making do, but it really feeds badly, tried a few new tips but no difference, it seems to work ok-ish at 200amps+ but in short-arc any lower amps, it makes a mess. Ordered a new reel of Bohler, came today, and it measured the same as the previous. I haven't fitted or tried it yet but I'm confident it will solve the problem. I'm using Binzel silver tips in an MB36, btw. The strange thing is, we had a suspected issue with wire at work about a month ago, now I order Lincoln/Esab/Bohler there, and we compared diameters of Esab and Lincoln, both came out very close, they use 1.0mm wire also with Binzel silver tips but in 501D watercooled torches, and it feeds fine. Anyone else had this sort of problem? Not sure why previous Esab reels have been fine on my setup... I refuse to go up a tip size because I shouldn't have to and I've never had to before.