1:1 scale in drawings is actually 96.3% - even when the printer can handle 1:1
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I noticed this problem a while ago, but now it's time to document it fully. Fusion does not print at 1:1 scale when it is set to 1:1; it prints at about 96.3%.
Here's an object that I made to demonstrate the difference. The object is a 250mmx100mm rectangle, with lines at 10mm increments and then 25mm increments. I extruded the segments to alternating heights of 1mm and 2mm (the extrusion is only used so that the drawing lines are clearer in the photo). Here is that drawing compared to an Incra metric ruler which has 0.25mm precision. The dimensions were added with the dimension tool in the drawing mode. 250mm, drawn to scale but not printed to scale
The obvious response to this is to suggest that my printer is shrinking the image, or that the default outer border is having some effect. So, first I removed the border, but there is no change. I should also note that there are no printer options available in Fusion, at least not with my setup.
250mm drawing isn't at 1:1 scale, without the default border
And so the next question is if my printer is scaling it down. I tested this by making a new drawing in a different program - the online version of SmartDraw - using a 1 cm : 1 cm scale and making similar lines. I had to add the lengths in manually rather than with a dimensioning tool, but the onscreen measurements and grid make it easy to correctly apply those. I used fewer lines for the sake of brevity.
SmartDraw correctly sizes to 100%
I made the drawing from the first two images entirely in Fusion this evening, without sending it through any other program, so there is no way that other software could interfere with it. All this was done on the same computer with the same printer. My printer is a Canon MG 5220, but I can also use other printers over the next few days and I expect I would see the same result. The paper size is 8.5"x11" and the printer settings in Fusion were for 8.5"x11". I have seen this problem with the exact same shrinkage amount in drawings that came with supplier parts months ago, so either they also use Fusion and this is a long-standing problem, or it's common across many CAD programs.
Personally, I was expecting to use 1:1 printouts to help form some components I am making. A 1:1 diagram can be printed, cut, and glued onto a part to provide all the markings necessary for the first pass of machining (see the ClickSpring youtube channel, he often uses that shortcut).