Extrusion width calibration using Simplify 3D

Notes:

This guide is for users that want to properly calibrate extrusion in Simplify 3D using a 0.4mm nozzle width and PLA filament

Click add to create a new process

1. call the process 'Calibration 0.4mm' 
2. select profile as your existing 'go to' profile 
3. set auto configure for material PLA 
4. set auto configure for material Medium 
5. set infill percentage to zero % 
6. click on show advanced- a lot more tweakable settings will appear. 

On the Extruder tab:

1. make sure nozzle diameter says 0.4mm, not 0.35. Change it if necessary. 
2. set extrusion multiplier to 1.0 
3. set extrusion width to manual 0.4mm 
4. leave retraction on, retraction 1.0mm if direct drive and 4.5mm if bowden with 0mm extra restart distance, 0mm vertical lift, 1600mm/min speed 
5. turn coasting off 
6. turn wipe off 

On the Layer tab:

1. this single wall calibration must be done for each type and brand of filament you use- PLA, ABS, and PETG will all require different extrusion multipliers. This was based on a default PLA process. For other materials, use S3D's default process settings for that material, and similarly create a new calibration process, modifying outline/perimeter and extrusion width to match your nozzle size. 
2. change top solid layers to 0 
3. leave bottom solid layers at 3 
4. change outline/perimeter shells to 1 (this sets the slicer to print a single wall) 

On the Cooling tab: 

1. Make sure Adjust speed for layers below 15 sec is set, and Allow speed reductions down to 20% is set. If you can, also play with cooling settings using a part cooler fan. 

Calibrating Marlin or Repetier firmware for correct extrusion feed

1. Calibrate and set e steps per mm in Repetier or Marlin such that when 100mm of filament is commanded to extrude, 100mm of filament is pushed thru your extruder exactly. 
2. With no hot end (just the extruder connected), mark with a fine black marker a line on the filament about 25mm from the end of the filament, and another line exactly 100mm higher, then feed the filament into your extruder. 
3. Command your extruder to advance in small increments using Repetier Host, Pronterface, or the Machine Control Panel Jog Controls Tab in Simplify 3D till the first line just disappears inside your extruder entrance hole using small manual steps. Then, command your extruder to advance 100mm using Repetier Host, Pronterface, or the Machine Control Panel Jog Controls Tab in Simplify 3D. 
4. If extruder steps per mm is set correctly in Repetier or Marlin, the second line should just disappear inside your extruder entrance hole. Adjust extruder steps per mm in Marlin or Repetier until this is exact and repeatable. 
5. This needs to be done once for the life of the extruder. If you change extruders, you will need to do this step again. 

Calibrating S3D and your extruder for correct extrusion rate

1. Download a solid 20x20mm calibration cube .stl (http://www.thingiverse.com/thing:34553) 
2. Open Simplify 3D, load the calibration cube, and slice it with the newly created process 'Calibration 0.4mm' 
3. Wait for print to cool, remove it from the bed, and measure the wall thickness with digital calipers- should read 0.4mm. If not, edit 'Calibration 0.4mm' and on Extruder tab, adjust extrusion multiplier up or down, save, and slice/print again until 0.4mm is measured. If extrusion multiplier is below 0.95 or higher than 1.05, re-check step 1 above, as likely e steps per mm is off. 
4. Once your settings have been confirmed in the Calibration process, go back and edit the extrusion multiplier settings in your standard process used to slice to those disovered in your calibration process. You can copy other parameters as well based on what you found works in your slicer. Remember to update any settings you change to all of the processes you might use.