I wonder if just including the aluminum tube that was effectively acting as a heat break would have been enough...

Really it seems like a problem of not understanding the environment, and testing (with margins) your replacement in it... 3D printing seems nearly entirely unrelated apart from enabling people to make parts.

An injection molded part, for a close more traditional analogue, would presumably have failed the same way here.

Also the glass transition temperature reported in the report is suspiciously low for ABS and the only source on the material is the owner saying the person they bought it from said... I wonder if it was just outright made out of the wrong material by accident.