This seems to be a bit like when you have a problem with your car and bring it to a garage.
Once the mechanic is there the car works perfectly fine.
I had made 6-7 attempts to print this with disastrous result.
They were all binned, so to get a sample to take some photos from I tried printing again, and it came out fine!
The only change I had made between the files was that I had added a 2 mm fillet to the top edge around the block.
Hard to see how that could make any difference.
Holes did come out better than expected.
A 3 mm precision steel shaft has a press fit in the 3 mm hole and a float fit in the 3.1 mm hole.
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geert_2 557
I think you would best post a couple of photos of the print, both a general overview, and close-ups. Anyway, expect the holes to become smaller than designed, due to the elasticity of the molten material when the nozzle draws the outline of the holes: it is pulled inwards. Just like a rubber band would be pulled inwards, if you try to lay it down in a circle and apply a bit of force to it. The smaller the hole, the worse this effect is. So, a 3mm hole is likely to end up as a 2 to 2.5mm hole.
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