Welcome, Josh! I suspect most people here use Simplify3D as their Dual Extruder software. I find it convoluted, but it is fairly effective. The 'Start Up' scripts are well-written and will ensure you have done everything you need, such as download new firmware, so I recommend completing those before...

First, I would try raising the extruder temperature by 5-10C.
Further diagnosis requires more information. i.e. whose filament? temperature? layer height? etc.

Jules wrote:(Can't let my hubs see that either....he'll want one.)

I will gladly send you the file, although this one is specific to a Browning 2000. I had no choice but to design my own; I could not find a manufactured pad to fit.

I finally had a successful print using PETG for the base and Ninjaflex for the flexible pad. The pad printed really well, at a very slow pace. S3D gave me an initial time of 1008 minutes, but as always it took much longer. I used very thin internal structures to provide the cushioning. I made slots ...

This large piece of Ninjaflex did not come out as well as I would have liked. I might have it a little too hot, 245C, so maybe that is why I get so much ooze. I had the top layers set for 4, so I do not know why the crappy top. (BTW, I should have remembered to put a chamfer on the edge.) I was also...

Ninjaflex sticks very well to PETG. I made this with 15% hexagonal fill, which makes it comfortably spongy. You can also see how well it sticks together under tension. Sizes are the same as last, except heights are 1/2.

[/quote]You'll get better results with even multiples of the thread width (0.80, 1.6 mm, etc)[/quote]

Looks as if I was off by a factor of 10. 0.8mm = 0.031" I will have to fix the file and try again.

"It looks like the lettering extends only one thread width into the switch body, which means the black extruder must start and stop very accurately. That rarely works as well as I'd like." I made the lettering depth 0.003" I did not calculate how many lines that would be, but I can make it, say, thr...

[quote="Jules"...print the text raised on the design in a different color.[/quote] I think I will try that anyway. The biggest PITA I had printing the covers on their sides was aligning the lettering into the cuts. There seems to be no way to align the pieces without lots of zooming in and very slig...

I have been trying this very thing for a while. I have some switch covers I need to replace, and I would like to get the lettering to be as precise as possible. I really thought printing the cover in white PLA with the lettering in black PLA might do the trick, but alas, it still leaves much to be d...