The 0.8mm overhang that sagged: dialing in the Hue console's feel

The console's top plate had a 15.6mm bottom relief under each switch pocket. On paper, fine. In the slicer, that relief created a 0.8mm inward overhang, flagged as an "Overhang wall," and on the first print the unsupported ring sagged. You could not see the defect from above. You could feel it the moment a switch went in.

The decision: stop trusting geometry that only looks right in CAD. The fix deleted the relief entirely and thinned the plate from 4.0mm to 3.5mm (2mm pocket, 1.5mm web), so the web now opens straight into the enclosure. Reprint came out clean with zero supports: about an hour of print time and 13.8m of filament on the P1S.

The tradeoff: a thinner web risks a mushy switch snap, so before committing the full plate I printed test coupons instead. The v2 coupon locked the web at 1.5mm: firm MX snap, no flex. Cheap coupons, expensive plate; print the coupon first.

The thing that broke along the way was my wiring notes, not the plastic: counting breadboard pin positions instead of reading the printed silkscreen labels mis-wired power once, silently. New rule in the build log: anchor to silkscreen, never to counted positions.

Current state: all six MX switches dry-fit in the printed plate and the 2x3 layout feels great in the hand. Phase-2 gate passed on a real part.