[@mmc_jake]

I like this idea, Ken. I’ve come across and tried a variety of techniques myself, so would be keen on sharing and learning from others’ experiences. We have talked internally in the past about an expanded resources section. In the meantime, we can use this thread.

I have seen a few similar techniques that use some sort of compliant element to accommodate different sizing. Angus from Maker’s Muse describes a design for a compliant hole that uses a slot: https://youtu.be/j6508J94VsA?t=319 (Note this really only works in a vertical print orientation.)

One of my favorite resources is the Design Rules from Hydra Research: https://www.hydraresearch3d.com/design-rules This has ~17 techniques for improving 3d printed designs.

Lastly, I had documented some interesting techniques in other thread:
https://forum.makersmakingchange.com/t/advanced-3d-printing-techniques/664