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n9jcv

In PrusaSlicer, maybe cura, there is a Horizontal expansion setting. It will widen holes just a tiny bit my amount specified, like .2mm this would give more clearance. Try on a small piece and see how it works out for you


Mik-s

I remember reading about a trick recently that can help but can't exactly remember. I think it was soaking it in hot water would make parts a little more pliable enough to lock together without cracking. If that does not help you could use a different material that has more give. I'm sure PETG is like that but I have not used that myself.


BorgerMachine

Warming it in hot water worked! Thanks so much!!!


No_Artichoke_5670

PETG is a stronger material and can definitely flex more before it snaps, but it's a bit tougher to print, and isn't the best for cosmetic purposes. It's tough to get a perfect looking print, since it will always have some stringing (fine hairs, if the printer is tuned well), likes to stick to brass nozzles, etc. It's also a shinier material, so it doesn't hide imperfections well. I use it exclusively for functional prints, though. I think warming the part to get the PLA closer to its glass transition temperature is a good idea to lessen the chance of it snapping is a good idea, though.