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Spline geometry and where contact and interference issues occur

While working in the student lab, one of my tasks that I’ve really enjoyed working on was creating a guide for spline tolerancing in using the Stratasys FDM printer to create ABS parts for prototyping. The goal was to create a reproducable set of part creating tools that students can use to help reduce tolerance errors in their prototyping.

While researching this topic, I found some resources that were helpful in understanding where most clearance issues originate in spline interfaces.

Spline geometry and where contact and interferance issues occur
Spline geometry and where contact and interference issues occur