Hi,
I think you have two major issues with the design here that means it will probably
not work in the real world. Firstly you are 3D printing threads. While this is possible
and you "can" get accurate threads, the limitations of the manufacturing process
with such things as material distortion due to uneven shrinkage mean that you are
very unlikely to get an totally accurate thread.
Secondly you are trying to bolt together two parts that have a gap between them.
For what purpose? Bolts may be able to in some situations clamp down two parts
but the clamping forces will not be even on both parts; ANY mis-alignment will
mean that the threads will not engage correctly and the mis-alignment will almost
certainly destroy the thread when the bolt is tightened to clamping torque. On top
of that, this attempt at joining is a failure point waiting to happen.
In short - this is a terrible solution. To get a proper join, at the very least, you will
need a coupler plate with at least two bolts on EITHER side of the gap. Another option
is to extend BOTH sides you want joined and put the Bolt through the overlapping
joint. This may also need more than one bolt because the joint will not be flush.
This is why the coupler solution might be better.
Exact cutting of the thread is not the solution you should be looking for. Re-designing
the whole joint to create something that will actually work is what is needed.
Cheers
Andrew
