Hardware, Enclosure, B_shell.scad, LED has Line-Line Fit, Bad For Assembly

[ForrestErickson]

Describe the Failure / Bug
A clear and concise description of what the failure / bug is. Describe the problem NOT the fix.

Short Summary of the expected behavior:
Assemble with out parts interfering.

Short Summary of the buggy behavior:
The 5mm LEDs had very tight fit to the B_Shell at all six locations.

To Reproduce
Steps to reproduce the behavior:

1. Printed with file: U_Box_V105_Krake_RevB_BShell_V4.0.stl
2. Printed with zero XY Size Compensation.
3. Printed by Lee in ABS, Printed by Nagham in PLA HS+.

[ForrestErickson]

In the file It appears that the LED diameter is set to exactly 5mm. The same as the LED.

Here is the parameter for the 5 alarm LEDs diameter. The Power LED is set elsewhere.

This diameter is a MAGIC NUMBER and should not be.

[ForrestErickson]

@nk25719
Here is the AI explanation of why "line-to-line" fit is bad.

A line-to-line fit (or "line fit") should generally be avoided in mechanical design because it is unstable, highly sensitive to manufacturing tolerances, and difficult to assemble. A line-to-line fit technically means the maximum material condition (MMC) of the shaft and the hole are exactly the same size, resulting in either a "zero-gap" (clearance) or a "zero-interference" (interference) state. [1, 2, 3]
Here is why this is problematic:

• Sensitivity to Tolerances (The "Almost" Effect): Manufacturing produces parts within a range of tolerance. If the shaft is at its maximum tolerance and the hole is at its minimum, the parts will not fit together. Because a line-to-line fit has no inherent "buffer" or "gap" built in, tiny inaccuracies in machining lead to interference rather than a smooth fit.
• Difficult or Destructive Assembly: Because there is zero intentional clearance, assembly often requires forcing the parts together, which can mar surfaces, create debris, and lead to difficult or destructive disassembly.
• Uncertainty in Final Fit: With a line-to-line fit, you cannot guarantee the outcome. Parts might be loose (vibration) or tight (press fit) on a part-to-part basis, causing unpredictable performance.
• Thermal Expansion Issues: Because the fit is already so tight, minor changes in temperature can make the parts expand or contract, turning a "perfect" line-to-line fit into a jammed assembly or a loose one.
• High Manufacturing Costs: To maintain a true line-to-line fit across many parts, extremely tight tolerances are required. This exponentially increases machining, inspection, and tooling costs. [1, 4, 5, 6, 7]

Instead of a line-to-line fit, designers should typically use a clearance fit for ease of assembly and movement, or an interference fit (when intentional, controlled interference is required for a permanent joint). [1, 8, 9, 10, 11]

AI responses may include mistakes.

[1] https://prototek.com/article/a-guide-to-tolerance-and-fit-in-mechanical-design/
[2] https://prototek.com/article/a-guide-to-tolerance-and-fit-in-mechanical-design/
[3] https://www.linkedin.com/pulse/how-understand-machining-drawings-st-cncmachining-ltd-upz0e
[4] https://tarkka.co/2019/02/20/fits-and-tolerances-how-to-design-stuff-that-fits-together/
[5] https://rapidaxis.com/blog/beginners-guide-to-picking-the-right-fit-in-engineering/
[6] https://xometry.pro/en-eu/articles/limits-fits-guide/
[7] https://accendoreliability.com/importance-fit-tolerance-clearance/
[8] https://www.fictiv.com/articles/engineering-fits-clearance-transition-interference
[9] https://www.fictiv.com/articles/engineering-fits-clearance-transition-interference
[10] https://www.studysmarter.co.uk/explanations/engineering/design-engineering/limits-and-fits/
[11] https://restoric.co.uk/2025/05/16/understanding-tolerances-and-fits-how-restoric-delivers-precision-in-every-manufacturing-drawing/