I've got a couple of Elu 96E's, one for hand held, the other for smaller inversion work.
After an extended run of MDF routing a few years ago (no dust extraction available, so clouds everywhere!) like David Savage's, the plunge was really poor and quite limited.
Being out of warranty, I thought i'd take it apart to see what the problem was...
Inside the plunge post apertures and the actual clam shell was absolutely packed solid with really fine dust, as fine as flour. The plunge posts had compacted it up inside so the plunge was less than it should be, and also stiffened it up.
Like the old sand art things at the seaside, the dust was in layers from different jobs over its lifespan, so it happens from the off it seems.
I would say that even the best routers, (and I still rate the 96 as one of them)despite having really tight bushings to keep dust out, will still let the finest, almost microscopic stuff through as there has to be some tolerance for movement, so it can settle inside and build up, especially with no dust extraction, or when inverted.
It's the nature of the beast as far as I am concerned, you can't lay blame at a manufacturers doorstep for an inherent part of woodworking life.
Sloppy bearings, mis alignment etc, yes, but clogging from dust build up is a day to day problem that can't really be laid at their doorstep as far as I am concerned, especially on a tool in a professional workshop used on a daily basis for about six months and used by more than one person...
IMHO of course!
cheers,
Andy