Testing done with Black Inland PLA sliced with S3D I almost always use 0.4mm nozzles, once in a while i will go with something larger. I am about to embark and a multiple roll of filament printing spree with well over 100 bolt holes. To prepare I printed off a couple test blocks testing m4 and m3 hardware clearances vertically and horizontally first with an 0.4mm nozzle at 0.3 layer height. I had to give a little extra clearance and reprint and got a passable result didn't think much of it. Here is where its a little odd. I decided that I should probably up the nozzle size as these prints are going to take a long time so I went up to a 0.6mm nozzle at 0.3 layers and reprinted the test blocks and now my holes are way to tight I would have to drill every hole out which I definitely don't want to do. I adjusted the model tolerances again and reprinted, the horizontal holes are fine but the vertical holes are still too tight especially for the m3 and while the horizontal holes are almost too loose for the m3. I created a new test print 20x20x10 cube with a 10mm diameter hole in the middle with fillets to round the edges. I get almost perfect measurements on the outer dimensions but the hole I measure is about 9.4-9.6mm in diameter (I was even slightly under extruding during this test to rule out over extrusion) Just to rule out esteps as the issue, I printed a 140x140 cube and measured with my calipers and the esteps seem spot on. I am thinking about trying a different slicer tonight to see if I can get a different result. Does anyone have any thoughts or suggestions?