OK I may have cracked it! Give these settings a try using latest orca nightly build:
- Wall order: inner / outer – gives outer walls something to stick to for overhangs
- Line width - internal solid infill: 0.4 -– assuming a 0.4 nozzle. For some reason orca uses internal solid infill line width for bridge line width. Since a bridge can never be wider than nozzle width (nothing to squish against for wider line) set this == nozzle size.
- Bridge flow ratio: 1.0 to ~1.06 – When less than 1 orca generates a significant gap between the outermost bridge lines and the inner bridge infill. Why, I’m not sure, but it does.
- External bridge density: 110-120% – This essentially moves the bridge infill lines closer together so they stick to their neighbors as they’re laid down. This is what you need the nightly build for so you get this pr that allows > 100% bridge density
- Thick external bridges: off – when this is “on” orca leaves a big gap between the outer bridge lines and bridge infill. Not sure why.
At least so far using a temp tower for testing this seems to massively improve bridges. They aren’t sagging under the fan’s pressure anymore because the infill lines actually stick together. Nice flat bridges on my temp tower, no saggy lines under each bridge anymore. The outermost line still seems too far separated from the infill and is sometimes a little loose on it’s own, but it’s still a lot better. I’m going to keep playing with it, but this is very promising.