Workflow for creating clearance between interlocking parts

[metd01567]

I'm fleshing out an alphabet for pseudo-typesetting signs.  Each character has an inner slot where LEDs reside, covered by a diffusion lens.  I've been printing the letters in ABS (stiff) and the lens in TPU (flexible).  While the TPU stretches nicely, I still need some clearance between the letter and the lens for proper fit.

You'll see there's an inset in the letter's LED slot to hold the lens.  I form the inset by creating a plug of the lens and cutting the letter with the plug.  Then I want to push the outer surfaces of the lens plug by .25mm to give proper clearance.  The lens walls used to be straight, and the push was easy.  I recently added bit of shape to the inset's cross-section so the flexible walls of the lens lay flat against the letter.  Since that change, the push fails for complex characters.  I've been creating a separate lens component from scratch (not shown in the attached design), to match the inset's geometry but with the proper clearance.  That doubles the workload, introduces potential for error, and creates a maintenance nightmare.

My desired solution would retain the cross-section's profile, but provide .25mm clearance between the two parts.  I could compromise on the profile if it saves significant design time, considering the number of characters I've got to do.

I'm open to any suggestions including style.  Once I start on the full upper and lower case alphabet, with numbers, etc, even a small improvement in workflow could save me a lot of time.  I'd also like to tweak the dimension with user parameters with minimal fixes to the 60+ character designs.

[g-andresen · Accepted solution]

Hi,

offset face and split body are your friends

günther

[metd01567]

I adjusted the lens size to account for cutting outward, and it works great, thanks.

In a perfect world, Press/Pull would have chain selection, and it wouldn't give up so easily.