MakerBot Industries

Also, I found using the Makerblock profilemaker, I often tell it I'm using a given layer height and then actually enter a lower number into carve in the skienforge profile.

Say I used 0.39 in profilemaker, but I enter 0.35 in skienforge. In theory, this would smash the filament each layer forming a better bond and it does very well with overhangs.

http://makerblock.com/profilemaker/

so again,basically here is my settings
I entered these values
Layer Height: 0.39 Thread Width:0.50 Filament Diameter: 2.88
but notice the program would return with 0.39 in Carve, but I put 0.35 instead when I edit my profile. This works very well for me.

1. Enter these settings as follows:"0.35" in Carve -> "Layer Thickness (mm)"
2. "1.28" in Carve -> "Perimeter Width over Thickness (ratio)"
3. "1.28" in Fill -> "Infill Width over Thickness (ratio)"
4. "30" in Speed -> "Feed Rate (mm/s)"
5. "1.5879" in Speed -> "Flow Rate Setting (float)"

Thanks so much for the help Jetguy! I'm not going to have a chance to mess with my Maker Bot until Friday, but I'm looking forward to trying out the ideas you mentioned! I'll post how it works for me this weekend.