3D Printer Tolerance Test

by amandaghassaei, published

3D Printer Tolerance Test by amandaghassaei Jan 15, 2015
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Tolerance tests for a high res 3d printer, designed with features beyond machine resolution (~1500dpi) to demonstrate how your printer/material fails. Must be printed on a machine that uses some kind of support material. Includes thin walls and wells up to 0.00063425in thick, a wide range of curvature (including gently sloping surfaces to test z axis resolution), a sharp peak, a cavity, and several moving hinges of varying tolerances.

testPrint- whole assembly in one file
testPrintAssem(7 files) - each solid body of assembly in a separate file
solidworks parts and assemblies also attached

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You dont need to print anything to test printers callibaration.
All you have to do is to hold the digital caliper in place and move it with stepper controls.
Motion reflected on the caliper will tell you how far off you are from what you told it to move.
I like to go by 100mm.

No need to print anything.

This will only get you within a few steps-per-mm. But will do nothing for bridge flow rate, temperature, and very little with extrusion width. And printing is required to know how accurately the slicing software and printer handles different tolerances and fits...compared to the shrink ratio of each filament.

Flow is very easily calibrated by looking at it.
IF you print 10x10x10mm cube and 100x100x100 with overflow of (about) 2 times too much, it will not make your model 2 times bigger, it will make your shell (sides and top and bottom) look smooshed.
Get rid of smooshed filament and thats all the calibration you need for the flow. Its eazy to see this effect when printing solid objects starting from 3rd layer and up (because 1st layer is typically too low to start with for adhesion purposes and is slightly smooshed)
This image shows too low of a flow rate (http://3.bp.blogspot.com/-n4fISj2ftoY/T_lcinWC3XI/AAAAAAAAHzI/9mzYq8uu_1U/s1600/DSC_1651.JPG) and this is too much of a flow rate (http://3.bp.blogspot.com/-wdr_Rm0mf6E/ToG_qi8kilI/AAAAAAAAAe8/HCrU3dixzLE/s1600/extruder_jam_hot_end_temp_too_low.jpg)
It should be like this (http://www.google.com/imgres?imgurl=http://theresnomon.co/wp-content/uploads/2015/01/calibrated_print.jpg&imgrefurl=http://theresnomon.co/2015/my-foray-into-3d-printing/&h=970&w=1041&tbnid=_lgW7FZL3qNhXM:&zoom=1&docid=kpD4saz21pARRM&ei=aLKNVeOqHc_HogTGn43oAQ&tbm=isch&ved=0CFMQMyhPME84kAM)