Joining failure

 From:  Michael Gibson
9350.9 In reply to 9350.8 
Hi Gord, well those look like the main things that just won't work at all. But there are also some areas where things are just off alignment by a small amount which may cause some problems with little slivery gaps or very small excess surfaces. Probably the 3D printing slicer is not going to like that kind of thing either.

Here's an example of that kind of thing:





Those pieces have a gap between them of only 0.0067 mm, it is kind of likely that your 3D printing slicer software is going to consider those to be badly formed areas that are intersecting each other and may not be able to figure out a clean slice through there.

It's not good in general to have such small gaps when doing 3D printing.

- Michael