The .9xxxmm is because your bed hight is pushing against the nozzle and spreading the filament like peanutbutter with a knife. The nozzle spreads the abs/pla outwards the same way. It would be fantastic if we can get thinner than .35 but its pretty much never gonna happen unless there are nozzles smaller than .35 mm.

If you measure the filament after its been extruded from the nozzle, (mine extrudes around .45mm.) So you cant expect a .35 mm nozzle that extrudes .45mm to extrude anything thinner than that. You might get thinner than .9xx with more experince and tinkering, but i couldnt get my prints to anything less than 1mm wide and be solid at the same time. It would just break with a tiny bit of pressure.

I think you are expecting a bit more than what is physically possible with our printers without modifications. The only 3d printers that i know of that are capable of going that thin are UV resin printers like the Form 1 from Form Labs, envisiontec, DWS etc. The technology is totally different and much more expensive than our $600 printers. For the price, our printers are just as good as any other makerbot or prusa that you will come across as long as you get to know the capabilities and limitations.

With that in mind, you should design your models within the physical limits and tolerances of the machine/material.

Hope this helps more than it frustrates you, but its just the physical drawbacks of filament printing vs. resin or other technologies. Good luck!!

So I just did a recalibration shell cube (1.0"W x 1.0"L x 0.5H") with a single wall thickness of 0.017"(0.42mm).  Ran the first print and readjusted the Extrusion Multiplier to dial in successfully to 0.017".

The issue is my outer dimensions on the square are 0.994" x 0.994"...can't see why this would happen; maybe it's normal.

Anyone experience this?  It will be important when things have to fit together.