Diameter Calibration for Holes and Bosses on Replicator 2

This project helps Replicator 2 owners print parts with more accurate diameters for holes and bosses. The problem comes from Arc Compensation, an issue caused by slicing software that makes holes print out smaller than they were designed and bosses print out larger than they were designed. This is only a real problem when you are making through holes, holes that will be tapped, press fit components, etc.

To solve this problem, I printed a bunch of different diameter holes and bosses, and measured each one with a set of calipers. I then plotted the expected diameters against the average error, which gives a calibration curve. The calibration curve allows you print more accurate diameter holes and bosses by accounting for the arc compensation errors during design. For example, holes with diameters less than 4.5mm have a 0.38mm error. So when designing a 3mm hole in your part, you would design it to be 3mm + 0.38mm = 3.38mm. Then, when you print out the part, the hole will actually come out to be 3mm. You can download the excel file with the measured data & calibration curve in the files section. Or, you can download the parts and run your own calibration for other slicers.

See the Instructions section for more detail on the process & excel file.