When I googled this setting, ""Top Layer Extra Expansion"" I got precisely 2 google results, neither of which actually explain what this feature properly does, and it is evidently not documented anywhere online. The first result goes to this forum in 2015, where one person tries to answer the question but doesn't actually answer the question: what does this setting do?
All S3D says in the program is: "Use this option to expand the top layer regions to provide increased overlap with the layer above"
On its own, this doesn't make any sense. The default I found it on is eg. 1.00 mm. And I find that whether I change this value to 0 mm, 1 mm, 5 mm, 10 mm, whatever, I cannot see one single thing different in the output sliced gcode, at all. On multiple different part files, too, some with flat tops, sloped tops, tops with crazy features, like engraved lettering, all sorts of parts, I can't see a single thing different from one slice to the next from 0 to 100 mm of extra expansion! What does this setting actually fricken do?