Hello Seesoe,
Have a look at the AO-101 Slic3r config files here: http://downloads.lulzbot.com/lulzbot/AO-101/software/current/slic3r/config/
You can see that for the 0.50mm nozzle, they provide 0.40mm and 0.30mm layer profiles. For the 0.35mm nozzle they provide a 0.25mm layer profile, and for the 0.25mm nozzle the profile is set to a layer of 0.10mm. Beyond that I guess it’s up to you to experiment.
FYI, I checked the Makerbot 2 specs (sorry for mentioning it guys
) and with a 0.40mm nozzle, they have three layer resolution settings: low (0.34mm), medium (0.27mm) and fine (0.10mm).
That’s odd. Using the afore mentioned Slic3r profile at 0.40mm layer resolution I get pretty good results, see this topic.
I think it is best working in mm. Slic3r can scale parts but STL is a polygonal (mesh) format. Surfaces are made of polygons rather that smooth surfaces. If you scale an imperial model by 25.4 in Slic3r to get it from inches to mm I guess the polygons will be scaled as well. You will get a much less refined model.
Otherwise, if you design your models in a CAD program, which deals with solids rather than meshes, then you could work in inches, scale your model up, and only then export to STL. That way you won’t degrade your mesh.
Normand