MakerBot Print is our newest print-prepration software, which supports native CAD files and STL assemblies,
allows you to interact with all your printers via the Cloud, and many other exciting new features.
I intentionally draw connectors that way so they would fit tighter together. I think it is better to sand them, then to have them dance around. I too had to send mine, for them to fit together.
I am very curious on how this quad will perform, so if you are willing to build 3 inch version, I am willing to design it :)