I have one ceiling vent that develops condensation to the point of dripping on the floor in my bathroom. I made sure the vent is sealed around the sheetrock, no obstruction to the air intake, clean filter. When I take the vent cover off it does not feel like there is any moisture in the inside (duct). Any thoughts on how to rectify this? I have no problems calling a HVAC company but it sure seems like I am missing something on an easy fix.

Has this always been happening or just recently with hotter weather?

I had the same and discovered a ducting issue. This only occurred in hot summer months, the duct insulation was allowing condensation and it moved down and out the vent.

I'd inspect the duct and vent for proper sealing and insulation. Sounds like condensation.

Its certainly only in hotter weather but it has been this way for about 2 years now? House is 17 years old now. I can't remember if this coincided with the new AC unit (variable stage)? I guess my next step is to get in the attic and trace that duct looking for holes?

If only in hotter weather my money would be on condensation.

If you can access the area I would start where the duct meets the register and feel for moisture and then start tracing it back to origin. The register needs to be fully insulated, if you see any metal that will need to be addressed and could be the issue.

thanks

Agree with Barnacle
Mine is closest to new HVAC & skylight, humid kitchen - all metal ducts
Began Great Stuff insulation near area
Best fix was replacing metal register with a plastic one from Amazon

https://texags.com/forums/61/topics/3382622

Leak around the supply register

When the AC is running how good is the air flow? You should be able to feel it blowing, not blow your hair hard but more than just feeling a draft. If it doesn't have good velocity it could be causing the grill alone to sweat. Is it happening all the time or only after a shower? Do you run an exhaust fan while you bathe? Can you access the attic and ensure that the register box has insulation on it?

It actually blows fairly hard. No correlation to the shower plus it's a big bathroom. I can access the space above the vent on this one. But I noticed a vent upstairs that is from another unit doing the same thing. We've had a lot of raccoon issues over the years which is now sealed off to all their access points but this may be some more aftermath of their destruction.