Where's the fun in using Shapeways? I was trying to turn this tolerance constraint into an interesting problem. Given the need for *little boxes* down through the ages -- e.g., for snuff, for cosmetics, etc. -- there have been all sorts of solutions to this problem. E.g., the Edo Japanese had their "Inro" boxes, which are pulled together with bits of string, and can sometimes be fabulously decorated: https://en.wikipedia.org/wiki/Inro One could easily make a miniature inro box for a USB device from relatively poor tolerance pieces. At 12:34 PM 5/27/2016, Bill Gosper wrote:

Henry, you've been cr@pped on. 3D printing is way better than that. Shapeways (et al) will make stuff out of almost anything, to almost any desired tolerance.