Pre-screening (conventional MEX). I established a baseline at 170 °C, 15 mm/s, and a 0.4 mm nozzle. Lower temperatures tended to warp/over-extrude, very slow speeds increased stringing, and the 0.8 mm nozzle under-extruded. These conditions informed the MPD trials.

Layer height. 0.1 mm layers consistently returned ~73% dimensional accuracy. Moving to 0.2 mm and 0.3 mm raised accuracy to the ~95% band (avgs 95.01% and 95.51%). However, 0.3 mm repeatedly showed an over-extruded first layer regardless of levitation setting.

Raster width. All tested widths printed, but 0.45 mm was slightly more consistent across runs than 0.3 mm or 0.6 mm.

Mover levitation height. A 2.25 mm levitation height held accuracy most stably; 1 mm and 4 mm introduced noticeably more variability.