Why thanks. Any other suggestions?

I calibrated my extruder; marked off 120mm, extruded 100mm, and adjusted accordingly. As for printing in another material, that's why I'm printing the fan holder for my extruder. I also have some Taulman n-vent and In-PLA, but I believe both require a fan. Does NinjaFlex require a fan?

I ran a 20mm cube. It came to X: 20.3, Y: 20.19, Z: 19.75. Not too shabby.

I stopped the print. It's a bit better w/ the slower speed. One thing is that for several layers, it wan't extruding properly.

Direct drive.

According to the specs from E3D, their Titan Extruder motor has a rated current per phase of 1.4A.

Here is the settings from [c]config.g[/c] for my drives:

[[language]]
; Drives
M584 X0 Y1 Z2:4 E3 ; set Z to Z and E1 drivers
M569 P0 S0 ; Drive 0 goes backwards
M569 P1 S0 ; Drive 1 goes backwards
M569 P2 S1 ; Drive 2 goes forwards
M569 P3 S0 ; Drive 3 goes forwards
M350 X16 Y16 Z16 E16 I1 ; Configure microstepping with interpolation
M92 X80 Y80 Z406.35 E1005 ; Set steps per mm
M201 X800 Y800 Z100 E1000           ; Accelerations (mm/s^2)
M203 X15000 Y15000 Z10000 E3600     ; Maximum speeds (mm/min)
M566 X600 Y600 Z100 E20             ; Minimum speeds mm/minute
M906 X800 Y800 Z800 E1400 I30 ; Set motor currents (mA) and motor idle factor in per cent
M84 S30 ; Set idle timeout

Here is my FFF file. I also started the print again dropping speed from 58mm/s to 40mm/s and it already looks better. The holes still could use to rounder/clearer.

@MoS-tekknix:

Otherwise it is hard to tell where to start

Wow, my bad. Taulman 910 @ 260º and bed at 45º. Bed is borosilicate glass with a thin coating of Elmer's Glue-All. Slicer is Simplify3D 4.0.0. Temps are based on what Taulman told me via support email. Printer is an i3 variant with an E3D Titan Aero extruder with Volcano hot end; .4mm nozzle. Board is a Duet Ethernet 1.0 running 1.19.2 firmware.

Now that I have my Duet Ethernet setup and programmed, now is the time to get everything printing properly. Please take a look at the attached pics of this part (fan holder) and tell me where I need to look to fix these printing fails. Thanks!

Click for more pictures here.