One thing you could try is another slicer.  Even though Slic3r is the mainstream now since it's integrated with Repetier Host, I find its not all that accurate sometimes.  At the moment I'm trying out Cura, which ships with the Ultimakers.  Quite a bit less settings than Slic3r but I'm already seeing improvement in tool paths with it.  One key feature is the overlap infill setting which helps connect the infill to perimeters nicely.  Not your particular problem but

ggunners wrote:

If I recall correctly, the basis for the measurement is the normal expansion of the filament as it exits the nozzle. We've been using 20% expansion, or 1.2 times the actual nozzle diameter. One of the calibrations is a single filament width per side empty cube. We adjust the "extrusion multiplier" until the single sides equal the expected expansion width. See: http://wiki.solidoodle.com/flow-rate

Right, I have done that calibration too.  So I guess there is not a big difference on setting your width to 0.42 or 0.48 mm, as long as it comes out to what you set it for on the calibration test.

Except that you are setting the tool paths with that number.  So if you set it lower than .48 and then wondering why your perimeters aren't connecting you've found your answer.  I have covered this extensively before.  Every variable affects other variables, of course you can tweak extrusion multiplier to get the correct extrusion but that's there as a necessary fudge factor just for extrusion volume.  Set the extrusion width to something absurd like 4 mm's and then look at the generated G-code.

If I recall correctly, the basis for the measurement is the normal expansion of the filament as it exits the nozzle. We've been using 20% expansion, or 1.2 times the actual nozzle diameter. One of the calibrations is a single filament width per side empty cube. We adjust the "extrusion multiplier" until the single sides equal the expected expansion width. See: http://wiki.solidoodle.com/flow-rate

Right, I have done that calibration too.  So I guess there is not a big difference on setting your width to 0.42 or 0.48 mm, as long as it comes out to what you set it for on the calibration test.

If I recall correctly, the basis for the measurement is the normal expansion of the filament as it exits the nozzle. We've been using 20% expansion, or 1.2 times the actual nozzle diameter. One of the calibrations is a single filament width per side empty cube. We adjust the "extrusion multiplier" until the single sides equal the expected expansion width. See: http://wiki.solidoodle.com/flow-rate

+1

I say was because of another problem I'm having now. I got it all dialed in and was gonna start trying .1 printing and ended up moving my setup and now I'm having issues that I think are motor related.

With the .35 nozzle we use .42, the .40 nozzle should use .48.

Source for these numbers?  I've been running my SD2 with stock 0.4mm nozzle at a default width of 0.42mm for a while and I get good prints.  This is from solidoodle's website where the recommend a width/ thickness ratio of 1.3 so for 0.3mm layers: 0.3*1.3= 0.42mm default extrusion width. 

http://support.solidoodle.com/hc/en-us/ … alibration

I'm not saying there is only one way to do it, just curious why you do it this way?

I cant remember what the stock nozzle size is but I think it is .4mm