I'm trying a print right now that uses 0 infill and 2mm shell. So far its doing great. I'll have to run the test again for this specific need cause this print is in wood fill and is set to flow at 130%. At least its the first time it doesnt clog at all
I'm happy to see that you also boost the flow... I'm always having the impression its more a hack to counter real issues
They don't truly overlap - it's more complicated.
I believe it will print from 75% to 150% of nozzle diameter so for .4mm nozzle that's .3mm to .6mm per pass. If you ask for a shell that is .7mm it does two .35mm passes. That means it positions the nozzle .35/2 mm (.175mm) inwards from the final finished edge and puts consecutive passes .35mm apart. Another way to think of this is that cura treats your nozzle as though it is a .35mm nozzle and extrudes only what a .35mm nozzle needs (underextrusion) and puts two passes .35 apart just like you would do with a .35mm nozzle. Even though in reality you have a .4mm nozzle.
I can see how this would improve adhesion between the 2 shells but you might be better off just increasing the flow by 10% or so. Or fix the belts to remove any backlash or play. Or print slower or hotter because maybe you don't have backlash but instead have underextrusion (too much pressure in the nozzle - plastic can't get out fast enough).
I always (almost always) set shell width to a multiple of nozzle diameter (e.g. .4, .8, 1.2, 1.6) as I get much better results that way (in my opinion). The only exception is for thin walls such as when I do text in which case I will often do .3mm shell. This comes out much better. I often simultaneously set the flow to 133%. But this is a special case.
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