This may be more for the ZMorph Team. However, you may find this useful. We recently wanted to know how small the ZMorph 2.0 could print. Also, we wanted to test what our designed dimensions would translate into when going to print. So we designed a model in standard sizes ranging from 0.020" all the way up to 0.200". We increased the diameters by 0.010" at a time. Here is a picture of the design:
This block was 1" x 1" and 0.1" high. Here is the STL file, if you would like to run your own tests:
HoleSizeTest.STL (98.1 KB)
We printed this using Voxelizer v.1.4.11 64-bit. Our preset was the default 1.75mm Filament. We did, however, modify it to be for ABS. Here are the settings we changed:
- Fan ABS
- Infill 10%
- Infill Type Honeycomb
- Power Raft ABS
- Small Perimeter Speed 10mm/s
- Voxel Size 0.25mm (no changes here, but included it for reference)
- NOTE: Regarding the Voxel Size, 0.25mm is a limitation of 9.8 mils in standard for the resolution. So it is possible that we need to decrease this when printing with these critical dimensions, say to 0.025mm which would give us a 1 mil resolution. We may print again using this to see if there is any difference.
Our American-made ABS was extruded at 250C onto a hotbed at 105C. Bed was pre-treated/pre-prepped with ABS Glue (Thicker version of ABS Juice) prior to heating.
We found that at the worst readings, the ZMorph printed 0.031" less than the desired hole diameter and at best it printed 0.010" less than the desired hole diameter. Below you will see our raw data as well as a series of charts showing our measurements.
As for why we need to know, we are working with optics and hardware that requires us to keep very specific diameters (ID/OD alike). We inspected our designs to ensure accuracy, but the actual printed product was off target.
Possible solution (ideas our team has been tossing back and forth):
Obviously, that is not to scale, but look at the color diagram. So in order to maintain correct hole size, the path would need to follow the GREEN nozzle path as opposed to the YELLOW nozzle path. This would ensure proper hole diameters.
Finally, below you will see our raw data along with a set of graphs. One set is in standard, one set is in metric. Our measurements were taken using precision hole gauges.
If you have any questions, please feel free to contact me or respond below. Thanks all!