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After watching what feels like hours of youtube videos trying to find an accurate way of doing this, I cant to seem a simple non destructive way of adding clearance to an object (specifically a key shape) in Blender.

I want there to be a clearance of exactly 0.6 mm in my object. I've tried using the solidify-boolean method of booleaning a cube with my key shape, then adding a solidify modifier of 0.6mm, but whenever I use the measure tool, it doesn't seem to remotely be close to the measurement I put in the solidify modifier. I apply all transformations to the key before I do this process.

I have a video describing the problem: https://imgur.com/a/GbqXkX1

EDIT:

For reference, I have my unit scale set to "0.001" and length to millimeters, as well as the floor scale in "viewport overlays" to "0.001".

For my specific situation; I am wanting to 3D print this model and have the arms be sliced and put together with gorilla glue afterwards by inserting the hand/wrist into the arm.enter image description here

I add a key to the hand/wrist, then Boolean out the arm with the key shape.enter image description here

Now since I am going to be 3D printing this, I want to add a clearance of 0.6mm, so I want the hole to be 0.6mm bigger to compensate for dimensional imperfections. What I usually do is; I union the key and hand together with Bool Tools (ctrl numpad +), solidify the Boolean cutter object with 0.6mm thickness, 1.0 offset, and have Even Thickness, Fill, and Only Rim enabled. I always make sure to apply all transformations with ctrl+A before and after this process. enter image description hereenter image description here I then Boolean out the arm with the key cutout that has the solidify modifier, and now I should have a fitting key with 0.6mm clearance.enter image description hereenter image description here

However, when I use the measure tool and enable snapping with edge center, I get 0.79 mm distance instead of the inputted 0.6mm in the solidify modifier. My only guess for why this would be happening is either I am using the measure tool wrong, or the solidify modifier is not super accurate. If there is any other way to achieve what I am trying to do, I would greatly appreciate it.enter image description here

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    $\begingroup$ You could probably do it with Geometry Nodes. It depends on what form it is and where you need the clearance. Could you please edit the question and add some screenshots with your object clearly visible and mark where you want the clearance and explain your specific situation? It's not really possible to answer this question in general for all possible cases in a single answer. $\endgroup$ Commented Jan 18 at 7:31
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    $\begingroup$ You're measuring 'in the mitre', centre-edge to centre-edge, which, of necessity, is greater than the thickness measured along the normal of parallel faces, unless you put a radius around the top edges of the cavity. If measured in the flat, it's more accurate, if not perfect .. this experiment looked for a thickness of .2m : imgur.com/a/CyS01JT $\endgroup$ Commented Jan 18 at 10:19
  • $\begingroup$ @MartynasŽiemys I added more screenshots and included an explanation of what I am trying to do, hope that makes it more clear. $\endgroup$ Commented Jan 18 at 13:44

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@RobinBetts is right, you’re measuring along a diagonal when the solidify modifier works parallel to the normals of the faces. For an isosceles right triangle with a hypotenuse of 0.793, the two other sides would be 0.56, and considering the faces that are being solidified are not quite right-angled in this scenario, it probably really is 0.4.

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