In Simplify3d's support settings one specifies the vertical separation between the support and the part in terms of a number of LAYERS. I suppose if you use 0 layers then the part and the support will then bond - unless you're using scaffold. So if you're printing at, say 0.3mm layer height, that means the gap between the support and the part is already rather large and the support fails to do what its supposed to. Apart from upgrading to Dual and using Scaffold, anyone have any suggestions?
that's an interesting idea.... and as a side effect faster printing will temporarily cool the nozzle a bit which will help further