Restore the confirmed file and refine only stud grip

The reference is p3003-febe17af-553f183c_PLA_2h25m13s.gcode, SHA-256 49a1704441f229bb247e3a86017a217ffeff279683e88e20315fe323c3c7b3b7. The reattached copy with “(2)” in its filename has the identical checksum. It was sliced with Creality Print 7.2.2.5483 on 2026-10-21 for 9 copies of 3003 on Creality K2 Pro, PLA, 0.4 mm. Its 2h 25m 13s estimate belongs to that original job.

Above-first-layer toolpaths are consistent with approximately 15.97 mm bodies and 4.76 mm faceted studs. A +0.030 mm whole-source clearance on the current 3003 mesh closely matches those contours. This is a toolpath inference; the original CAD and Nexlock fit metadata are not recorded.

The G-code contains toolpaths and process settings, not the original STL or exact CAD provenance. The current geometry baseline is an inference from those contours. The earlier 1h 59m file remains superseded. Saved profiles and Tested evidence are retained with their original settings.

1. 1

   Select K2 Pro, PLA, a 0.4 mm nozzle and source 3003. Open All tests → Previous setups and choose Restore the K2 Pro stud trial.

2. 2

   Start with Starting comparison and Recorded motion. Sample 1 is the unchanged inferred reference baseline. Samples 2–5 increase the original faceted stud diameters only.

3. 3

   Prepare the candidates. The body, cavity, tube, roof, grid and Z planes stay fixed, with no exterior-wall inset or receiving adjustment. Geometry candidates may share one plate when it fits.

4. 4

   After cooling, compare both connection directions, full engagement, exactly one engaged stud and a three-brick staggered wall. Choose the smallest increase that holds and releases cleanly.

5. 5

   Repeat the winner three times; complete measurements, ten cycles and the ten-second single-stud hold on every copy before saving Tested.

These values are additions to the whole diameter, not per-side wall offsets. The reference stud is approximately 4.76 mm; the Standard range reaches approximately 4.80 mm. Sample summaries measure the prepared studs’ maximum X/Y span, rather than only the requested value. This envelope is not a minimum gripping width; use the Connection geometry audit to compare directional widths. Fine and wide retain the unchanged baseline.

All body and receiving vertices below the roof retain the baseline positions, and every Z coordinate and stud center stays fixed. A tighter printed stud cannot also tighten a genuine stud entering the unchanged printed underside. Test the intended connection in both directions.

This restored-reference test explicitly selects the recorded custom motion by default, even if ordinary parts use installed slicer speeds. The same process applies to every stud candidate. It retains 80% part/auxiliary fan, the first-layer fan delay and the native machine’s pressure-advance ownership.

Faster interiors & travel is optional. Outer walls remain 40 mm/s at 1000 mm/s², top surfaces 20 mm/s at 400 mm/s², and the first layer stays unchanged. Inner walls use 90 mm/s at up to 3000 mm/s², sparse/internal solid infill up to 160 mm/s at the recorded 1000 mm/s² print acceleration, and travel 300 mm/s at up to 8000 mm/s². The 8 mm³/s limit, 0.12 mm layers, flow, shells, temperatures, cooling and geometry remain fixed. These are Nexlock trial values within the checked hardware limits. Minimum-layer cooling, overhang and small-perimeter controls are inherited from the installed preset. The original file recorded 8 seconds minimum layer time and small-perimeter threshold 0; inspect these before comparing time.

At 0.40 mm width × 0.12 mm layers, 160 mm/s is bounded below 8 mm³/s. Short paths, acceleration and minimum-layer cooling can still dominate. Compare the actual slice at equal quantity; no measured reduction or sub-hour production time is promised. Retest fit, corners and flatness after changing pace. For larger gains, separately compare layer heights or calibrated maximum flow in the installed slicer; neither is silently changed here.

Print samples shows each actual geometry ID, the maximum X/Y stud span and unchanged wall/receiving dimensions. Native slicer settings are deliberately identical across stud candidates because only geometry varies. Process tests retain an applied reference-stud fit and show the native fields that change.

Preparation rejects candidates with identical geometry and process. Companion checks returned vertices, triangles, orientation, spacing and process values. Open a prepared native file as a project; STL and ordinary geometry-only 3MF do not automatically apply slicer settings.

Keep X-Y hole/contour and shrink compensation at zero in the slicer because the mesh already contains its fit adjustment. The recorded 0.15 mm elephant-foot compensation acts separately on initial layers. Existing saved recipes retain their own values.

MachineBlocks documents independent stud, wall and tube calibration. Its offsets are not interchangeable with Nexlock values. Klipper explains that pressure advance can reduce corner blobbing and depends on extruder, filament, temperature and speed. Preserve the existing value until it is calibrated for the actual spool.

Prusa explains maximum volumetric flow and variable layer height as limits and possible time-saving tools. Variable layers can affect surface stepping and mating heights, so inspect the slice and verify connections. CNC Kitchen’s pressure/flow video is a research example, not a ready-made brick recipe or proof of LEGO-equivalent performance.