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Dimensional Accuracy and Fit Tolerance

Fix holes that print too small, pegs that are too large, and multipart designs that do not fit.

Start hereCalibrate flow and mechanics first, then use model-specific clearance or hole compensation. Do not globally scale an axis until measurement proves a true axis error.

First safe actionRun the first safe check and change one variable at a time.

Proof targetA small representative test no longer shows the original symptom.

Problem, repair steps and target result for dimensional accuracy and fit tolerance — Match the failed area to the visual before changing a setting.

Repair progress0 of 7 complete

Step 1 of 7

Use accurate calipers and measure a known calibration part.

Visual reference while completing step 1 of dimensional accuracy and fit tolerance — Keep the problem and target visual open while you make this change.

Why this matters

Extra material changes features.

Setting or checkXY compensation

Apply cautiously; it affects many features.

Expected result

Repeated parts measure consistently.

Step 2 of 7

Fix first-layer elephant foot before judging XY fit.

Visual reference while completing step 2 of dimensional accuracy and fit tolerance — Keep the problem and target visual open while you make this change.

Why this matters

FDM holes often print undersized.

Setting or checkHole compensation

Prefer when only internal holes are consistently small.

Expected result

Fit works in the intended orientation.

Step 3 of 7

Calibrate flow/extrusion.

Visual reference while completing step 3 of dimensional accuracy and fit tolerance — Keep the problem and target visual open while you make this change.

Why this matters

Axis motion does not match command.

Setting or checkFirst-layer compensation

Use for elephant foot, not global size.

Expected result

Bottom and upper dimensions match.

Step 4 of 7

Check belts, pulleys, steps/mm or rotation distance only with a reliable measurement method.

Visual reference while completing step 4 of dimensional accuracy and fit tolerance — Keep the problem and target visual open while you make this change.

Why this matters

Cooling changes final size.

Setting or checkWall order

Can influence dimensional accuracy.

Expected result

Compensation is documented per printer/material.

Step 5 of 7

Test holes/pegs in the same orientation as the real part.

Visual reference while completing step 5 of dimensional accuracy and fit tolerance — Keep the problem and target visual open while you make this change.

Why this matters

CAD assumes perfect manufacturing.

Setting or checkXY compensation

Apply cautiously; it affects many features.

Expected result

Repeated parts measure consistently.

Step 6 of 7

Use slicer hole/XY compensation only after mechanics and flow are correct.

Visual reference while completing step 6 of dimensional accuracy and fit tolerance — Keep the problem and target visual open while you make this change.

Why this matters

Extra material changes features.

Setting or checkHole compensation

Prefer when only internal holes are consistently small.

Expected result

Fit works in the intended orientation.

Step 7 of 7

Update CAD clearance based on repeated process capability.

Visual reference while completing step 7 of dimensional accuracy and fit tolerance — Keep the problem and target visual open while you make this change.

Why this matters

FDM holes often print undersized.

Setting or checkFirst-layer compensation

Use for elephant foot, not global size.

Expected result

Bottom and upper dimensions match.

Controlled test log

Change one variable, then record what happened

This keeps temperature, retraction, speed, mechanical, and material tests from blending together. The history stays private in this browser.

Open proof report →

No controlled tests logged yet. Record the first change before adjusting a second variable.

Do not repeat the full print yet

Prove the repair with a small test

Test model20 mm calibration cube plus fit coupon

Setup

Use the target profile and measure after the part fully cools.

Pass condition

Dimensions and mating features fall within the required tolerance.

If it still fails

Axes or holes remain consistently oversized or undersized.

Recheck visual diagnosis

Complete the repair steps, run the proof test, and record the result.

Only if the proof test still fails

Next strongest repair paths

Do not stack these changes. Open one related guide based on the evidence that remains.

First LayerElephant Foot Fix

Open this related First Layer guide when the first repair path does not fully explain the remaining symptom.

Open guide →

Visual guide for flow rate and extrusion multiplier calibration

CalibrationFlow Rate and Extrusion Multiplier Calibration

Use this next when the symptom changes with extrusion width or wall thickness.

Open guide →

Visual guide for pressure advance / linear advance tuning

CalibrationPressure Advance / Linear Advance Tuning

Use this next when corners, seams or speed changes leave blobs or gaps.

Open guide →

Matched next step

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