On the surface, this looks straight forward, but allow me to give some history.
User Story
I want to be able to print objects I design, with a +/- 0.5mm dimensional tolerance, and have circles and regularly polygons print with a consistent radius and all lines and angles within the polygon are congruent.
Symptoms
See the photo attached to this post. About 2 weeks ago circles began printing ever-so-slight out-of-round. Evidence
This is a standard S5. It's about 2 years old, and has around 250hrs of print time on it. It's always printed small objects smaller than they should be (some times as much as a full mm) but for the most part that's not a problem as long as holes are actually circles or regular polygons since any scale deviance in size can be resolved in the model or with some simple hand tools.
I asked around and did some reading and most suggested tightening belts or re-calibrating. I opted for the latter--I'm a bit remiss to do any disassembly on this machine. I calibrated the Z-axis and got stuck. The printer would fail to start the XY calibration, complaining about a height difference. While searching for an answer, I noticed there was a firmware update from 5.8.1 to 5.8.2. Did that.
A post on this forum lead me to realize it might be a problem with the lift switch and so I watched that carefully and found it was missing the bracket to flip the switch. I recalibrated the lift switch and could now print the XY calibration pattern.
The thing I noticed at this time was that the Y portion is exactly the same size as on the paper calibration print out (in the Y direction), and all the tick marks match up with the numbers on the paper. The X axis, however, is smaller that the calibration rectangle (in the X direction) and starting at the left-most position (-), gets further away from the numbers as the you look to the right (+). Still, using this guide it looks like +1 is the way to go, but that doesn't help.
If X and Y adjustments are the same [(0.5, 0.5),(1.0,1.0), or (1.5,1.5)] circles are ovals, and polygons are skewed, but right angles with sides perfectly on the X and Y axis are straight. If the X adjustment is larger than Y, I get a right angle trapezoid when printing the skirt, but printing a rectangular object prints a perfectly right-angled parallelogram as one would expect.
I've attached a photo of the before changes (before Z calibration) and after changes (current).
Before is Ultimaker White Tough PLA, from extruder 1(AA 0.4); the same setup I've used for a couple years.
Current is Polymaker Teal Polylite PETG (CPE) from extruder 2 (AA 0.4);
Changes:
Z-axis alignment
Firmware update
Calibrate lift switch
Calibrate XY
New Filament (first time using non-ultimaker filaments) using settings as recommended by SandervG in this post.
Conclusion
Something I have done has taken me from bad to worse and I'm outside my realm of expertise to resolve it.
I am not concerned about problems with infill or material adhesion at this point.