ganadyne

After extensive research this post seemed to describe the problem I was having the best: 5-10mm of some but not all single width line segments were underextruded as shown after a travel move, and none of the settings that would logically fix the issue really addressed it properly. My model also has several single walled features which would be consistent with the OP's hypothesis of cura not slicing properly when switching between different width thin features. After a large amount of time playing with every setting that could remotely have anything to do with outer perimeters, I found that disabling the "Compensate outer wall overlaps" setting made the single wall extrusions behave as intended. Phew! Hopefully that helps anyone else who is seeing this issue. I don't know why this setting would change the way a single wall feature is extruded. I'm inclined to think it is a bug.

Hi All, Here is an update: The rounded corner issue is due to the bowden feed system and can be remedied by using the correct print settings. This is pretty well documented around the forum and elsewhere online. We had issues printing fine single wall details (0.5mm wide single layer line features on a surface) where the printed lines had extremely variable widths. I suspect this is also caused by the bowden feed system not regulating pressure in the print head well. We remedied this issue by using a 0.25mm print head which was adequate to get the single wall feature accuracy we needed. In an attempt to fix the various and hard to understand dimensional accuracy issues which made interlocking parts not fit together, we meticulously modified and test printed our model file one line width at a time so that it would print patterns that do fit together. After this was accomplished and some test prints had the correct printed dimensions, we rotated the model 90 degrees on the print bed only to find that the model has systematically shifted its dimensions. We get a distortion of up to 0.75mm between X and Y oriented prints for a dimension that should be approximately 100mm using the ESD PETG required for our application and tech support recommended print settings, and a systematic 0.5mm distortion using toughPLA with Ultimaker engineering profiles. Printing the same part on different parts of the print bed also results in variations in dimensional accuracy, but we have not done extensive characterization of this effect. I suspect the significant distortions between the X and Y axes were causing a lot of our headache when trying to tune an interlocking print model on the S5. After doing a lot of test prints and debugging with Ultimaker support, they have determined that our printer is working as intended. For a comparison, we have printed over 600 of these interlocking parts on the Prusa we used as a proof of concept machine with few problems and predictable model file vs measured print dimensions. We wanted to upgrade to a printer with easily replaced modular components and better build quality, but these tolerance issues are enough to dissuade me from moving our printing program onto the S5 platform. So, I am returning the S5 and taking a hit on return shipping and a restock fee. There is a lot to like about the S5 - the modular print heads, large print area, robust cable management, nice enclosure and air manager system, etc. If you do not need very precise and accurate prints, it may serve you well and live up to it's reputation. Unfortunately that isn't the case here and we did end up spending a lot of time and money with little to gain. As an afterthought, I do wonder if printers with large build area tend to have more XY accuracy problems generally. There is another thread here where users with a lot of Ultimaker experience claim the smaller format printers have better accuracy and I imagine the S3 and S5 have a lot of design similarities. Gabriel

Hello, I've been using a Prusa i3 mk3s for about 6 months making custom IC shipping containers and decided to upgrade to an S5 a little under a month ago. I've had issues with interlocking prints being oversized, which is pretty well documented around this forum. Most people recommend simply using a negative horizontal expansion value to bring the print size closer to the .STL size. While I have some success using a -0.1mm horizontal expansion value for outer dimensions, my model has some fine 0.4 mm wide lines on the surface which get completely removed by using this horizontal expansion value. I have to say, this is very disappointing. I will echo the many other reports I have seen of people running into XY dimensional accuracy issues with this printer and say that I am very surprised a Prusa mk3s produces much more accurate prints with less work. At this point I would not recommend anyone purchase the S5 if dimensional accuracy is important to them. It seems like a software or firmware fix would be appropriate to solve this issue; does UM plan to address this issue, or are there any plugins that will adjust outer and inner walls only and leave single wall features alone? Thank you, Gabriel

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