OrcaSlicer Tolerance Test: Complete 3D Printing Guide

OrcaSlicer’s tolerance test solves a common problem in 3D printing: parts that do not fit correctly when assembled.

This simple test identifies the exact tolerance your printer needs to create parts that fit the first time. In just 10 minutes you can get a reference value that will improve the accuracy of all your designs.

This guide explains the complete process: how to run the test, interpret the results and apply what you learn. No fuss, no detours, just practical information to get better results in your 3D printing.

Key Points of the Tolerance Test

• The test takes only 10 minutes and uses 3.10 grams of filament.
• Measures tolerances between 0.0mm and 0.4mm to identify the optimum fit
• Helps to avoid loose or tight fitting parts in your projects
• It must be performed for each type of filament, as shrinkage varies
• It is accessible directly from the Calibration menu in OrcaSlicer.

What is the Tolerance Test and Why Should You Take It?

The OrcaSlicer tolerance test is a calibration tool that allows you to determine the dimensional accuracy of your 3D printer. It consists of a simple model with six hexagonal holes, each with a different tolerance, and a hexagonal piece to test the fit in each hole.

Tolerance in 3D printing refers to the difference between the theoretical dimensions of a model and the actual dimensions of the printed part. This difference arises from multiple factors: the characteristics of the printer, the material used and the printing parameters.

Performing this test provides you with three specific benefits:

1. Knowing the optimum tolerance to design parts that fit perfectly
2. Reducing material waste by avoiding reprints
3. Save time by achieving accurate results from the first attempt

Best of all, this test requires only 10 minutes of printing and consumes only 3.10 grams of filament. It’s a minimal investment for a significant improvement in the quality of your projects.

Step 1: How to Access the Test in OrcaSlicer

Accessing the tolerance test in OrcaSlicer is very simple:

1. Open OrcaSlicer
2. Go to the upper left hand corner of the interface.
3. Click on “Calibration”.
4. Select “Orca Tolerance Test”.

The model will be loaded automatically. From here, you can use your usual settings to slice the model, or make some specific adjustments.

Step 2: Model Preparation

Once the test model is loaded into OrcaSlicer, it is time to prepare it for printing. The model consists of two parts: a rectangular base with six hexagonal holes and a hexagonal test piece.

To obtain accurate results, you should avoid using certain functions that affect dimensions:

• Do not use X-Y hole compensation
• Disables X-Y contour compensation
• Maintain standard settings for speed and temperature

These functions could alter the precise dimensions of the test, which would invalidate the results. The objective is to evaluate the natural dimensional accuracy of your printer without software corrections.

Here are the steps to prepare and print the model:

1. With the model loaded, check that it is correctly oriented on the platform.
2. Apply the print settings, ideally based on previous calibrations such as the temperature test. In case no specific configuration is available based on other tests, use the default orcaslicer configuration.
3. Slice the model
4. Check the preview to make sure everything will print correctly.
5. Export the G-code file and take it to your printer.
6. Let’s print!

Step 3: Performing the Test

Once the printout is completed, follow these steps to draw conclusions:

1. Allow the model to cool completely to room temperature. This step is crucial, as the material may shrink slightly as it cools.
2. Use the hex key or an Alen M6 wrench and try to insert it into each of the six holes in the base. Each hole has a different tolerance:
   • Hole 1: 0.0mm (exact same size as part)
   • Hole 2: 0.05mm
   • Hole 3: 0.1mm
   • Hole 4: 0.2mm
   • Hole 5: 0.3mm
   • Hole 6: 0.4mm
3. The objective is to identify the hole where the hexagonal piece fits best. A “best fit” means that:
   • The part enters without excessive force
   • Once inserted, it has no play or lateral movement
   • It can be removed without difficulty, but it does not fall under its own weight either.
4. Note the tolerance value of the hole that provides the best fit.

This value will indicate the natural tolerance of your 3D printing system to the filament used.

Step 4: Interpretation and Application of Results

Once you have identified the hole with the best fit, you know the optimum tolerance for your specific printer and filament. This numerical value (0.0mm, 0.05mm, 0.1mm, 0.2mm, 0.3mm or 0.4mm) has immediate practical applications.

To apply the result in your slicer and projects:

1. In original designs: If you are creating parts that must fit together (such as gears, hinges or connectors), add the tolerance obtained to the size of the hole. For example, if your optimum tolerance is 0.2mm and you need a hole for a 10mm shaft, design the hole with a diameter of 10.2mm.
2. On existing parts: If you print a model that you did not design yourself, you can use selective scaling in your laminating software. Apply a scale factor to the inside dimensions based on your tolerance.
3. Use with the OrcaSlicer horizontal compensation parameter: Once you know the tolerance value, you can set the“XY Compensation” parameter in the software. Use exactly the value obtained in the test.

• Note: Depending on your case, you may have to enter the value as negative (-0.2mm) if you want to reduce the size of the outer parts.

This setting will cause OrcaSlicer to automatically compensate the dimensions of your models to achieve the precise fit you determined with the tolerance test.

For parts with specific holes, there is also the “XY Hole Compensation”, which you can set to the same value obtained to ensure that the holes have the correct dimensions.

A practical example: if you determined that your optimum tolerance is 0.1mm, when designing a male-female assembly system:

• The male part must maintain its original dimensions
• The female part (the gap) should be increased by 0.1mm on each relevant side.

This information is especially valuable for printing functional mechanisms, snap-fit parts, and components that require relative movement to each other.

Considerations by Type of Material

The tolerance varies significantly depending on the material used. This is mainly due to the different shrinkage experienced by each type of filament as it cools.

Important recommendation: Perform the tolerance test for each type of filament you usually use. Even between brands of the same material (e.g. different PLA) there can be significant variations.

Frequently Asked Questions about the Tolerance Test

Do I have to do the tolerance test every time I change filament?

It is not necessary to do this with every new coil of the same type and brand. However, you should repeat the test when:

• Switch to a different type of filament (from PLA to PETG, for example).
• Try a new brand that you have not used before.
• Modify mechanical components of your printer
• Make significant changes to the print settings

What do I do if no hole provides a perfect fit?

If the best fit seems to be between two values (e.g., between 0.2mm and 0.3mm), you can:

1. Use the intermediate value (0.25mm) for your designs.
2. Go for the higher value if you prefer looser assemblies
3. Choose the lower value if you need firmer joints.

Does the tolerance test work with all 3D printers?

Yes, this test is compatible with any FDM (Fused Deposition Modeling) printer. The specific function “Orca Tolerance Test” is only available in OrcaSlicer, but you can find similar models in repositories like Thingiverse or Printables if you use other software.

How does the printing temperature affect the tolerance?

Temperature can significantly influence the results:

• Higher temperatures tend to produce higher flow, reducing dimensional accuracy
• Lower temperatures may improve accuracy, but affect adhesion between coats

For optimum results, test at the temperatures you normally use for each material.