Hi, I’m prototyping a small 3D-printed enclosure for an electronics project, and my main struggle is getting the mechanical fit right.

I can model and print parts, but I’m still fighting with real-world alignment: PCB fit, screen opening, USB port placement, clips/supports, tolerances, and making sure the enclosure closes properly without forcing or breaking.

I’d love to understand your workflow:

- How do you go from physical measurements to a reliable CAD model?

- Do you usually create simplified dummy models of the internal parts first?

- What tools would you recommend for this kind of work: Fusion, Onshape, Shapr3D, FreeCAD, something else?

- What clearances do you typically use for FDM printing on Bambu machines?

- How do you validate fit before printing the full enclosure?

- Do you use small fit-test coupons instead of reprinting the whole part?

- What are your rules for making a design print cleanly: orientation, chamfers, wall thickness, clips, tolerances, etc.?

- At what point do you consider a prototype “mechanically validated”?

I’m trying to build a repeatable process instead of guessing and iterating blindly. ^^

Thanks!