As a result, we'll need to oversize the drill holes by 0.01 to 0.02 inches.
In addition, using self-tapping screws forces some of the material to move out of the way, which can cause stress and fractures in the plastic. The molten plastic that comes out of the extruder also has a habit of "melting" a bit around the edges, which can cause holes to shrink. Most fused filament fabrication (FFF) 3D printers, like our LulzBot, do not have great tolerances or resolution (e.g. For the lid, we'll want the screws to be able to freely spin, so we'll use the free fit drill size, which is 0.1285 inches. These holes will be put into the base of the enclosure. You can see that for a #4-40 screw, we'll need to drill a hole with a diameter of 0.0890 inches ( tap drill size) for the screw's threads to bite into the material. Take a look at this tap and drill size chart from Michigan Tech. As a result, we'll want to look up the sizes of the holes we'll need. We'll be using #4-40 screws to affix the lid to the enclosure. 3DHubs: How to Assemble 3D Printed Parts Threaded Fasteners
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