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Thanks for the feedback laird. The wing-catching "lip" is definitely in the geometry, and it printed OK on my Replicator 1.

Maybe try adjusting your layer height? It's by necessity fairly small because it's an internal overhang.

can't speak to your issues with the vial's native cap, though, since
there's a wide variety of cap styles out in the wild. Your solution
seems like a good idea.