Got a TAZ5 a few months back, and having a huge number of spools of 1.7mm filament left from my Makerbot nightmare, I wanted to modify my TAZ5 to run the 1.7mm. Purchased and swapped out a .4mm nozzle/1.75mm filament hexagon hot end. Tweaked some settings and found that setting Cura to 92% flow rate, .4mm nozzle and 1.75mm filament gave me the best prints.
But even after optimizing that, I still get corners that are bumped out, as well as some parts printing ‘fatter’ than they should be - as in I’ll print an item with a hole, and a peg that should fit that hole, and after printing the hole diameter is too small and the peg diameter is too wide, and it does not fit.
Thinking that I’m still pushing out too much filament I lowered the flow rate some more - but then I had layer adhesion issues. I don’t think the flow rate can safely go any lower.
What else could be causing this? Some images below to show what corners look like. These were printed with PLA (I hate ABS, no matter what I do large prints curl off the print bed, not worth the tinker time. PLA just WORKS for me). All corners shown in these pics should be hard 90 degree corners.
Part of the bad adhesion shown in this pic is due to a try at less than 92% flow rate. The more important part is seen from the side, as opposed to above, how far out the corners are bulging.