Summary

Update: added 0.15 and 0.25 tolerance testers.

Print to test tolerance needed for a box lid.

My results with PLA (BLUE):

Tolerance (all four sides):

0.0mm: no possibility of getting lid onto box

0.1mm: very tight, lid can go on but could become permanently affixed

0.2mm: tight enough to stay on but loose enough to come off easily, could be enough for a light use lid

0.3mm: easy on/off of lid with no excess tolerance, probably good with snapping points

0.4mm: easy on/off lid with some excess tolerance, may be good for snap or hinge points

0.5mm: too loose, too much excess tolerance

My results with TPU (WHITE):

0.0mm tight to get on, stays on snuggly, not difficult to remove

0.1mm a bit easier to get on, stays on snuggly, not hard to remove

0.2mm easy to get on, fits snuggly but can easily come off, might be good with snapping nubs

0.3mm very easy to get on, doesn't stay on by itself well, needs snapping support

0.4mm too loose

0.5mm too loose

This thing was made with Tinkercad. Edit it online https://www.tinkercad.com/things/kZed3mvyeM4