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I snapped the part off the build platform, lined it up in the caliper, ran that 1-72 screw through it, and It Just Worked.
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This confirms a suspicion I’ve had for a while that the XY stages don’t have the positioning accuracy required for this level of detail when printing at any reasonable speed.
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Unfortunately, the designers arranged things so that the ballast resistor for each string sits directly above the last LED of the adjacent string.
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Several different people surely noticed this situation and none of them were sufficiently empowered to fix the problem.
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Of late I’ve noticed more of a smell, so I figured it was time to replace the filter…
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So I cranked the right side down by 0.10 mm (just over 1/6 turn) and changed the G92 setting to Z1.50 to move the plate up by 0.05 mm.
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The Z axis motor drives a four-start leadscrew that moves the Z stage and the thingomatic.xml file specifies 200 step/mm = 0.05 mm/step.
