3DPrinting

Make two separate parts in CAD. You can join them as separate shapes in a Parts Workbench compound or using the Mesh Workbench tools. Then upload the meshed file into the slicer. Empirically tune the gaps to suit your printer.

Just be absolutely sure that the two parts do not overlap in some intersection. The slicer will absolutely try to print twice in the same place.

Personally, I like to use manual inserts or layer changes. Print your text separately in one color. Recess the text in negative for a few layers. Then add a print pause where you drop the lettering into the designed voids and continue the print, letting the voids and bridging bond the inserted letters.

I was messing with a similar issue with my laptop GPU cover design from a few weeks ago. I wanted the layers to separate between the patterns and how the slicer was pathing . I did a bunch of tests and still need to print a final version but uploading the first layer as multiple compounded meshes is the solution.

If you design the 0,0 location of the parts so that they import into PS already aligned but as separate meshes, you can also use the elephants foot or other unique settings to manipulate how each section prints.

Have you tried printing on a raft?

This is a resolution issue, so think about X & Y settings rather than Z settings like layer height. You need to reduce the line width and/or use a smaller nozzle like 0.2mm. You might also have a bit too much squish on your first layer which you could measure by printing a line and measuring it with calipers and comparing the slicer value to the actual value to see if there's any difference.

I'm not familiar with PrusaSlicer but Bambu Studio has a wall generating setting called "Arachne" which does a better job of generating the small features/walls you need for text even with a 0.4mm nozzle. You might see if there's a comparable setting for Prusa.

Just a thought: Try making the first layer of letters empty so the letter fill is actually a layer 2 bridge.

A trick I have done is printing the first layer solid in a transparent filament, then layer 2 as 2 color.

Super cool to see an update on this. Thanks for posting, since it will help the community!!

From the other post I remember you said that having the letters in the top layers didn't work for you, because that meant a lot of support material to remove.

From what I understand, your product consists of two parts. The large part with the letters and a counter part, which is just a flat piece.

So why not put the letters in the flat piece? That way you can print them either way up.

Besides printing issues: If I were a user of these adapters I'd be fine with what you got - it's readable, and I wouldn't expect high definition on this.

Did you calibrate flow rate, retraction and z offset? Teaching Tech has a pretty thorough guide for all things calibration.

I was thinking you could inset the letter boundaries on the letters first setup, but it looks like you only get 2 walls out of the slicer. Maybe try setting it to not outline the walls at all in letter first mode?

I’m not sure if any of the tips will translate well to your project, but this is another project that worked with small lettering: https://youtu.be/e7K3BXWmipk

That being said, I printed this project, and the results were kinda ‘meh’ even after loads of manual cleanup. Probably one of the most tedious prints I’ve ever had to do.

Maybe play with the first layer line width.