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i found a website about play-free fastening of aluminium extrusions, and thought you might get some good ideas from it to fasten your 3d printer together without needing to drill, making it tighter and more accurate.

Here's the link:

http://www.industrysearch.com.au/News/Play-free-fastening-technology-for-Aluminium-Extrusions-31545http://www.industrysearch.com....