Thank you for all the helpful advice. I appreciate it very much.
Playing around with the adaptive layer heights does provide "fixed" support interface layers in some cases, but unfortunately not in all places.
It kind of feels like I have to work around a bug in cura all the time, which just feels frustrating after several tries.
I have looked at previous cura versions and found that this bug originated with cura 15.1 and the new support structures.
Along with the change in the order in which the outer layers are printed, I am constantly having to adjust settings on otherwise very suitable profiles for my S5 Pro bundles.
Interestingly, this order has been reversed for the metal filaments from BASF, which are now being heavily polished...
Long story short, I think I will go back to cura 4.13.1 for the time being. The Cura 5 versions just don't feel smooth yet.
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GregValiant 1,346
Because "where" a slice goes through a model is dependent on Initial and Layer Height then changing the numbers changes where the slice is in the Z. Moving the slice up or down slightly can often make a difference. Those numbers also have an effect on where the top of a model actually ends up.
In the case of your model, it has a couple of Roofs that aren't an easily divisible distance apart. You can tune one, then the other is wrong. But there are ways to fool Cura. Sometimes they aren't obvious.
Make these changes and take a look.
.28 Initial Layer Height.
.151 Layer Height.
Enable Adaptive Layers.
A couple of things to consider:
Turn off Bridge Settings. The overhangs of this particular model are cantilevered and Bridging won't work anyway.
Change the Support Overhang Angle to 55°. The chamfers are 45° and don't need support and at 55° you will knock about 20 minutes off the print time. (The max overhang angle is a function of line width and layer height. Generally, up to about a 63° overhang doesn't require support but quality can be better if you keep the Cura setting below 60°.)
I would consider this a bug, but it's inherent in the way Cura currently works in regards to Layer Height. I don't see a fix getting much traction with the UM Cura team in the near future as it would seem to require a change in what is a very base feature of the way Cura works.
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