Filler isn't reaching the outlines, distortion of outlines

[rurwin]

Any ideas what's causing this?
[img]https://dl.dropboxusercontent.com/u/966 ... 153916.jpg[/img]
The filler isn't reaching the outlines, and there seems to be some distortion to the outlines.
The printer is an Orion. The filament is the PLA shipped with the printer. I'm using MatterControl with the default PLA configuration.
The one thing I haven't done is to swap out the extruder arm with the one that was sent, I assume as a recall replacement, but I haven't seen any reason posted for that replacement. I'd rather get comfortable with the printer before taking it to pieces.

I've checked the filament diameter -- 1.73mm, so pretty close anyway but changing it didn't make any difference.
I'm getting good bed adhesion.

The first couple of prints were much better than this -- The blinky is just about exactly the same as the sample shipped with the printer and the somewhat larger cup-holder adapter printed very well with just a few stringing issues.

Then I decided to design this key-fob thing because it would be neat to have a two-part thing and be quick to print.

Is this because the part is too small and detailed to print well, or are there setup issues here?

[Xenocrates]

I suspect it's a combination of infill overlap and track width settings, with them being mismatched with the layer height that's causing the gaps, and that the distortion of the perimeters is cause by poor adhesion, either to the bed or previous layers, due to the distortion already present.

[Polygonhell]

Looks more like a mechanical issue to me.
something is loose somewhere, that looks like pretty classic backlash for a delta printer.
Look how the hole in the top image is rotated/skewed, it's unlikely to be just a slicer issue.

[rurwin]

Thanks for the replies.

Would this be caused by a significantly bad calibration of a single axis? Because there's a good chance one of the towers is/was not hitting its limit switch.

[mhackney]

Yes, that would cause all sorts of problems. It must be triggering or it wouldn't home but if the switch is loose or not triggering consistently you would get bad results. If you had the original orientation of these parts on your print bed we could probably tell you which tower was the culprit.