Job printing too small ... where should I look?

I am creating a Power socket holder for attaching a PSU to 4040 extrusion. There will one for each end of the socket, attached by a TPU lug.

At its heart, it is a hollow cuboid, external size 62x38x24mm, and internal void of 58x27x22.

I have created this in fusion, exported it as a step file, created a new project in Bambu Studio, inserted the STEP file onto the build plate.

When I use the Studio measuring tools on the object, Studio confirms that the objects dimensions are the same as the fusion original. The Studio scale settings also confirm the external dimensions,with the scales all at 100%.

However, when I print the object, the object is printing smaller than expected. When I measure the physical dimensions (internal and external), they are 3mm less than expected in every dimension (2.9 mm but subject to my measuring skill!), both internal and external.

Where should I look in Studio, or on my h2c, for the discrepancy between the Studio/Fusion dimensions and the smaller final output dimensions?

(I have had no issues with out jobs that I have created, or from MakerWorld models)

6-Bar Switched Power In.3mf (32.5 KB)

Studio version 2.5.0.66

Thanks.

Update/Observation. The print seems to be about 3mm short in all 3 planes … it is not proportional to the size of the model. I am not sure if this is relevant though!

Slight bump because I am still confused as to how an object in bambu studio shows one dimension and prints out at a different dimension and I do not know where to turn next.

I may have done something wrong in fusion but once the step file comes in and measures 55.5 mm prints at 50 mm … it is no longer a fusion issue (AFAIK).

Your measuring skills are definitely suspect. The picture with the calipers shows 50.23mm on the digital screen, but the actual scale on the calipers is around 55 or 56. You probably just need to calibrate the calipers before taking your measurement. You do this by fully closing the calipers and then pressing the “zero” button. Any time you turn on a set of digital calipers you need to confirm they are zero’d before taking any measurements.

6 Likes

Thanks for the reply.

That is what I thought … the number of times I have measured the dimensions, internal, external, wall thickness etc. The callipers were reset to zero, and I see the same result on my other zeroed callipers … It must be me somewhere … these forums are some of the most helpful I have encountered. If nobody has a suggestion then I would posit user error! I think I will just move on and start a new model from scratch

Your calipers are not zeroed, the scale clearly shows 55.â– â–  while the read out shows 50.23.

3 Likes

I think the physical measurment is actually indicated by the line almost dorectly above the 50 mark, not by the total amount amount of the ruler exposed. If correct that would make the digital readout correct.

No, close the calipers and read the scale.

1 Like

I would say shrinkage, but 3mm is A LOT of shrinkage. I agree, check the calipers. I always find the cheap digital calipers to lose steps as you get bigger, often by a lot at the end of the run. I have a good set, but still re-zero every time I turn them on just in case. Measure a known object and double check them.

Try making a simple box of those deminsions in the slicer and print it out and measure it. If you are getting the same result on two different zeroed calipers as you stated then I doubt it is your measuring unless you are really skewing the caliper to the flat surfaces.

Edit: You can also just put the box down on a piece of paper and trace the outside with a sharp pencil and then measure the lines with a ruler.

Don’t waste your time designing another model. The calipers are definitely not zero’d. Maybe they are faulty or maybe you are misusing them, but they are definitely not reading correctly on the digital screen. The good news is that your printer seems to be printing the model reasonably accurately. The analog scale on the calipers shows that. Just look at where the jaws of the caliper line up with the scale. The left jaw aligns with zero and the right jaw with 55’ish. If that still doesn’t convince you then just use a normal ruler to measure that side of the part. It’s going to be 55mm (~2.25 inches).

That line you are seeing is a step down in the caliper jaws that allows the inside jaws to overlap when closed. It’s not related to the scale in any way. If it were, it would align with the edge of the part being measured, which it doesn’t. It is possible that he is zero’ing the calipers by referencing that line rather than fully closing the calipers. That would actually explain a lot.

1 Like

The irony is that they got the wrong answer form the right tool.

If they’d just used a cheap school ruller to measure it they’d have gotten the right answer with the wrong tool.

Not really relevant to anything, just a funny observation about how things go sometimes.

1 Like