Curious regarding your mandible prints & the pit holes, is there an overhang or 'lip' formed that covers your pit detail plates?. Or is a styrene plate or similar material added top & bottom surfaces?.
Does the printed mandible structure come out at exactly 2" thick?
I only recently noticed that the armour plating only partially covers the pit holes, yet a lip is visible around the entire diameter.
Meaning that much of the overhang starts with the original acrylic used to form the mandibles themselves.
It doesn't appear to be very thick though. Perhaps 1/8" and certainly no more than 3/16". The picture below is of the upper P/S aft pit and it is only half covered with styrene armour plating.
I understand that you are limited to some degree with the files that you are using to create the model when 3D printing. Unless you make massive alterations along the way.