Fit Testing Reference
Use this page as the troubleshooting map when a clicker does not feel right.
Common Symptoms
| Symptom | Likely cause | Next test |
|---|---|---|
| Parts will not assemble | Clearance too small, elephant foot, over-extrusion, or rough seam placement. | Measure mating faces, inspect first layer, try compensation on the affected axis. |
| Moving area is fused | First layer squish, brim/support contact, or insufficient clearance. | Inspect layer preview and retest with first-layer or compensation changes. |
| Click is weak or mushy | Flexible area too thin, wall layout too soft, material too flexible, or layer direction is wrong. | Compare wall count, orientation, and filament stiffness. |
| Clicker rattles | Clearance too large or printed walls undersized. | Measure printed features and reduce clearance or compensation. |
| One side rubs | Warping, uneven cooling, seam blob, or asymmetric geometry. | Rotate the model, inspect seam position, and compare left/right dimensions. |
| Keychain loop breaks | Layer direction or wall count is weak for the load. | Change orientation, add walls, or document the safe-use limit. |
Measurement Notes
Record measurements with calipers when possible:
- Designed outside dimension.
- Printed outside dimension.
- Designed hole or socket size.
- Printed hole or socket size.
- Actual clearance between moving parts.
- Whether the issue is global or local.
Fit Language
Use consistent terms in the guide:
- Fused: parts that should move are bonded by the print.
- Tight: parts move or assemble only with force.
- Snug: parts assemble with light pressure and stay seated.
- Free: parts move without binding.
- Loose: parts rattle, wobble, or detach too easily.