Hole Calibration Pack – Vertical / Horizontal / Floating Hole Tests (Parametric Fusion 360 File)

📌 Hole Calibration Pack – Holes That Actually Fit

This calibration pack includes every test you need to understand how to design holes that fit consistently in 3D printing, no matter what printer, filament or slicer you use.
These are the exact test pieces shown in my YouTube video, where I explain how each hole behaves depending on its orientation and how to design them properly in Fusion 360.

🎥 Full explanation video:

📁 What’s Included

STL files for all vertical, horizontal and floating hole tests

Parametric Fusion 360 file where you can adjust:

Real diameter of your rod / screw

Nominal hole size

Nozzle diameter

Tolerance values

Hole geometry (circular, teardrop, hexagonal, slotted, etc.)

All models update automatically via User Parameters (FX) in Fusion 360.

⚠ Important Note About the Fusion 360 File

I am actively working on improving the parametric Fusion file so it can adapt cleanly to any diameter and nozzle size.
There may still be cases where some geometry does not update perfectly depending on the combination of parameters.

If something breaks or fails to regenerate:
— you can still create your test holes manually
— the YouTube video fully explains how to design every hole from scratch
— feel free to adjust the sketches directly if needed

Updates will be uploaded as soon as improvements are ready.

🧱 1. Vertical Wall Holes

These holes are printed horizontally inside a vertical wall, which usually causes deformation on the top surface due to internal overhangs. That’s why the geometry matters a lot.

• Standard Circular Hole

Tends to collapse slightly at the top → poor dimensional accuracy.

• Teardrop Hole

Removes the unsupported overhang and keeps a much more accurate diameter.
This is the best option for dimensional precision.

• Hexagonal Hole

Requires more clearance but grips extremely well due to the six contact points.
Ideal when you need a tighter, more mechanical friction fit.

📌 2. Horizontal Surface Holes (Rod Inserted From Above)

These holes rely on friction, since the rod enters vertically.

• Circular Hole with Tolerance

Simple, but the fit changes over time. Friction wears out quickly.

• Circular Hole with Vertical Slot

Allows the wall to flex slightly → much more stable and repeatable.
Great for parts that are assembled/disassembled frequently.

• Dual-Tab Elastic Hole

The most controlled and professional option.
Two elastic tabs flex evenly and hold the rod firmly without excessive friction.

🪝 3. Floating Surface Holes

These holes are printed over empty space, meaning supports often deform the internal shape.
Two clean solutions:

• 0.2 mm Sacrificial Layer

A thin membrane closes the hole during printing, leaving a perfect bridge.
Simply remove it with a deburring tool afterwards.
Works best on large flat surfaces.

• Dual Perpendicular Bridges

Ideal for small holes, such as transitions from screw head to screw shaft.
Prints cleanly with no supports.

🧪 How to Use These Tests

Measure your rod/screw diameter accurately.

Adjust the parameters in the Fusion 360 file.

Print all variations in one plate to compare.

Determine which tolerance + geometry works best for your printer.

Apply those values to your real designs.

🖨 Printing Recommendations

Layer height: 0.2 mm

No supports needed

Works with PLA, PETG, or any rigid filament

Standard speeds are fine (precision depends on geometry, not speed)

🙌 Author

Designed by Iker Líbano – KNINcustom
More tutorials, guides and tests available on my YouTube channel.