So I'm having the exact same issue and have posted about "ejection route inconsistent" on another thread. Have had the issue for 3 years and Sig had it for 10 days, ground down the M4 feed ramps and I did not have any time to retest. Started shooting again recently. I have a lot of ammo that looks like ....
I've done everything (stronger buffer spring, H2 buffer, 5 coil heavy duty ejector spring & insert, detail cleaning, etc) so far except go to an H3 buffer and take apart the gas block piston to inspect/clean. Mine has maybe 500 rds of mixed ammo (.223 hunting, AE LC 55gr FMJBT, IMI 55gr, etc, etc) and various magazines (gen 2 & 3 PMags, D&H, Palmatto State Armory, and Tapco) and it really makes very little difference. The least failing appears to be Hornady TAP SBR 75gr which is very expensive ammo to train with. FWIW, It's a 10 piston w/suppressor set on smallest gas setting. I plan to do a few more things in trial, then put it back in the hands of Sig. Thanks to this group, I'm learning bunches.
A number of times it has done this ....
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