These settings (in Ultimaker Cura slicer) worked very well for me:

• Material:
  • 1.75mm PLA (roughly 600g worth!)
• I have an Anycubic Mega X printer. It has a print area capacity of 300mm x 300mm x 300mm. You will need at least 238mm (9.37") x 234mm (9.22") in the XY plane, and 89mm (3.5") in the Z (height) axis to print these parts as I've designed them (this includes a 10mm raft on all sides). Remember that you can rotate the part so it prints diagonally! In summary:
  • Print Length Max (includes 10mm Raft): 238mm (9.37")
  • Print Width Max (includes 10mm Raft): 234mm (9.22")
  • Print Height Max: 89mm (3.5")
• Raft HIGHLY Recommended:
  • Raft width (aka Extra Margin): 10mm
  • Raft air gap: 3mm (to make it easier to remove the raft!)
  • Raft top layers: 2
  • Raft top layer thickness: 0.4mm
  • Raft top line width: 0.4mm
  • Raft top spacing: 0.4mm
  • Raft middle thickness: 0.6mm
  • Raft middle line width: 0.8mm
  • Raft middle spacing: 1.0mm
  • Raft base thickness: 0.48mm
  • Raft base line width: 0.8mm
  • Raft base line spacing: 1.6mm
  • Raft top print speed: 7.5mm/s
  • Raft middle print speed: 5.625mm/s
  • Raft base print speed: 5.635mm/s
• Walls:
  • Wall thickness: 1.2mm
  • Wall line count: 3
  • Fill gaps between walls: Everywhere
• Quality:
  • Layer Height: 0.4mm (same as my extruder diameter)
  • Initial Layer Height: 0.4mm
  • Line Width (including ALL sub-settings in this category): 0.4mm
  • Initial Layer Line Width: 100>#/li###
• Top/Bottom:
  • Top Surface Skin Layers: 2
  • Top/Bottom Thickness: 1.2mm (= 0.4mm height/layer * 3 layers)
  • Top Layers: 3
  • Bottom Layers: 3
• Infill
  • Infill Density: 100% (because I want it as strong as possible and it's only 0.25" thick to begin with!)
  • Infill Line Distance: 0.4mm
  • Infill Pattern: Lines
  • Infill Layer Thickness: 0.4mm
• Support:
• Note: I didn't need any supports. This was a design decision and it worked out very well. However, generally I have my Support settings set to the following so it will detect when I need overhangs:
• Support Overhang Angle: 65 degrees

The goal is to get them to come out at least as good as these...

Don't let the gremlins move your cheese in the middle of the night...

Huzzah! It's done printing! Now it's time to clean it up. I used a wood rasp, a metal rasp, a Dremel with a sanding drum, an xacto knife, and of course a cutting board.

Here's a side-by-side comparison of before and after using the knife and rasps only:

Work in progress...Stay tuned!

TBD

TBD

TBD