I’m not sure if I’m being clear about what happens. You can see the same thing happening to Agnius here:
Numbering the cells 1 to 8 where 1 is closest to the viewer and 8 is furthest. As he pushes the last cell (cell 2) in, the cell 3 pops out a little bit. He then pushes that one in and cell 4 pops out. He’s then working out his way towards the last cell until all are all the way in.
Hmm. Got you. I haven’t experienced this but now I am wondering what could be changed in the design of the box or the tabs to solve this issue? Any ideas?
I have personally found the spacing between the cells a bit less. In design it’s 18.3 if I remember correctly. I think 18.4 might be sufficient. That probably solves the popping in and out because there is hardly any space and 3D printing imperfection makes it worse. Secondly the foam could be a bit thicker to allow for more tolerance in dimensions. But not sure how it would affect the compression.
When printing, scale that axis 1% and it will be fine. If the lids close, they keep them in place and the cells are aligned. If you see a bulge in the lid then it might be a problem.