I've been doing some troubleshooting on my issues with filling in the top surfaces of small walls, and determined it would be really beneficial to get some actual mathematical definitions of what all of these settings are. Basically, I've grown tired of guessing at what some of these things really mean and working through trial and error.
1) What exactly is the "extrusion diameter"? Is it just the diameter of the hole in the nozzle? Is it something else? Is there a reason one would enter a value other than the hole diameter in the nozzle?
2) What does the "auto extrusion width" check box do? How is it related to the extrusion diameter? If I put some value in this box what happens with that value?
3) How is the "minimum infill length" evaluated? If I crank that number way up (say 25) or way down (to say 0.1) what will happen?
4) When I check the box for "generate support material" in the FFF settings does that interfere in some way with "manual supports" that I defined prior to this point?
5) Is there a difference between selection 100% infill and going to the "other" tab and selecting "include solid diaphragm every 1 layers"?
6) Based on all of these settings, how wide of a "bead" of material is actually being applied with each pass of the head? How is this width calculated? This is apparently somewhat critical, as if I have too many "outline/perimeter shells" called for, then I get voids in my part.
I've carefully looked at the "tooltips", and googled a bunch of stuff, and installed Slic3r now to try and get a better handle on the terminology, but I guess I'd like to see some of this more spelled out directly from the Simplify3D folks, as I suspect I'm either assuming what things mean incorrectly or just flat out not understanding how some of these settings are related and it is causing me to get unusable parts.