Third version. Finally nailed the overhangs.
Process
- v1: walls too thin, collapsed at layer 40.
- v2: doubled walls, but the flutes lost their crispness.
- v3: kept thin walls, added a 1mm chamfer at every flute edge, printed clean.
What I learned
Layer height 0.12 is the floor for this geometry. 0.16 visibly stairsteps the flutes. Anything finer than 0.12 isn’t worth the print time.