thanks for your reply!
I didn't see it actually printing the defect as it was at the back right corner of the builtplate (14h full built plate print - 450grams)
From the preview in Cura it looks indeed to be at the start of the outer line. Retract on layer change and retract before outer layer were not checked. However before he starts printing the outer layer, he fills in a small gap in the opposite corner parts, maybe there is retraction (although combing is set to 'not in skin') but he definitely has a travel move of 220mm before starting the outer wall.
i used the same chamfer on outside and inside wall, so corner is a bit wider than the rest of the parts wall thickness - next designs I'll use fillets and make sure wall thickness stays constant to try to avoid having to fill in these parts.
Ss it best to design a part wall thickness to an exact multiple of the line width (so line width 0,8mm => part thickness 3,2 or 4mm) or just slightly less?