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Why are my 3D-Printed Holes Too Small?

3D printed holes end up too small due to a combination of thermal polymer shrinkage, inner perimeter extrusion calculations, and downward filament sag across horizontal arcs. You can easily overcome these issues by designing built-in tolerances in CAD, adjusting your slicer’s horizontal expansion settings, reorienting prints vertically, or utilizing mechanical reamers for precision fits.