Thanks a lot for the support! I got everything working.
There are just a couple of surfaces in your object that have have been trimmed by the boolean where the underlying surface's control points are a little bit larger than the active trim boundary - how can I fix this? I tried unjoining all surfaces and running ShrinkTrimmedSrf but nothing happens. Thanks!
I'm having one more issue with the export. Some parts are 12mm thick (same issue with 24mm) and the back side lines can be seen through the geometry (they are not hidden lines). Is the any .ini tweak that can fix this?
Front
Back
Front orthographic
The selected lines can be seen through the model
PDF export Back view

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