I was using this model at 100% infill to test extrusion:
The printer is an old Printrbot which I converted to Klipper, so I'm doing some tests to ensure correct parameters.
ABS filament 3 mm (not 2.85 mm, measured in multiple points), 230°C hot end (optimised with temperature tower), 100°C glass bed. The extruder was calibrated by extruding a known length of filament. The extrusion was checked by printing a single walled cube and was within tolerance of the caliper I used. I used no cooling fan (except, manually, for the first two layers on top of the support to ensure optimal bridges).I skip cooling with ABS to avoid warping, since the air around is colder (no enclosure).
The top surface comes out perfectly indicating a perfect extrusion multiplier, but the outermost perimeter doesn't bond with the second one, see photo:
Something I've never seen before is that the whole print is somehow thicker in a corner where the nozzle stops before raising, and the walls tend to expand with height, so in fact I may have an excessive extrusion, see photos:
The settings for slicing are (from the gcode, abridged):
; generated by PrusaSlicer 2.2.0-alpha2+win64 on 2019-12-23 at 18:44:54 UTC ; external perimeters extrusion width = 0.45mm ; perimeters extrusion width = 0.45mm ; infill extrusion width = 0.45mm ; solid infill extrusion width = 0.45mm ; top infill extrusion width = 0.40mm ; support material extrusion width = 0.40mm ; first layer extrusion width = 0.30mm ... ; avoid_crossing_perimeters = 0 ; bottom_solid_layers = 3 ; external_perimeter_extrusion_width = 0 ; external_perimeter_speed = 50% ; external_perimeters_first = 0 ; extra_loading_move = -2 ; extra_perimeters = 1 ; extruder_clearance_height = 20 ; extruder_clearance_radius = 20 ; extrusion_multiplier = 1 ; extrusion_width = 0 ; fill_density = 100% ; fill_pattern = rectilinear ; first_layer_extrusion_width = 150% ; first_layer_height = 100% ; first_layer_speed = 30 ; gap_fill_speed = 20 ; infill_every_layers = 1 ; infill_extrusion_width = 0 ; infill_first = 0 ; infill_only_where_needed = 0 ; infill_overlap = 25% ; infill_speed = 80 ; interface_shells = 0 ; nozzle_diameter = 0.4 ; only_retract_when_crossing_perimeters = 1 ; ooze_prevention = 0 ; perimeter_acceleration = 0 ; perimeter_extruder = 1 ; perimeter_extrusion_width = 0 ; perimeter_speed = 60 ; perimeters = 2 ; retract_before_travel = 2 ; retract_length = 0.5 ; seam_position = aligned ; skirt_distance = 2 ; skirt_height = 500 ; skirts = 1 ; small_perimeter_speed = 15 ; top_fill_pattern = rectilinear ; top_infill_extrusion_width = 0 ; top_solid_infill_speed = 15 ; top_solid_layers = 3
How can I solve the problems of the perimeters and of the irregular shape?