This makes me want to dive in a little more again. I get a little frustrated with Fusion sometimes because it feels so… constrained. Haha. I want to go through your whole approach here though and see. There’s a few things you mentioned that I hadn’t considered/thought of.
The threads tool in Fusion 360 is… expansive but limited. Ha. I wish there was a thread tool that gave some ability to customize a few aspects beyond just selecting standardized sizes. I feel like I’ve gone through all the options it provides, and there’s just no specific plastic/print friendly threads.
Oddly enough creating threads in something like 3dsmax is pretty simple in comparison. Well, I mean plastic threads. Machined threads would be a little different.