One of the most challenging things to do and maintain print quality with an extrusion style printer is to print a solid object (100% fill).
A student recently came into our shop to print some small parts in PLA. They were 15mm long with solid connecting tubes 4mm in diameter, and he insisted that they had to be solid.
After a few attempts using support created in Makerware, it was obvious we were going to have to create our own solution. The issue ultimately came down to cooling time. There was just no way to run the part slow enough to prevent warping, and permanent bonding of the support to the part. We modeled in a solid support with a gap to the part of .3mm to start. The part fused solid, so there was definitely not enough gap. We bumped it up to .4mm for the next print. We saw positive results on the sloped surfaces, but the horizontal surfaces still fused solid.
Eventually we found the equilibrium. A gap of .6mm between support and part on horizontal surfaces, and .3mm on surfaces at an angle worked great.
Tags: 100% infill, 3d printer support, 3d printing, 3dp, Flash Forge Diagnostics, Flash Forge Parts, Flash Forge Torture Tests, Flash Forge Troubleshooting, Flash Forge Tweaks, PLA, rapid prototyping, solid infil, support