Need help with thin connector

My neighbor had his mailbox hit and the mailbox signage (containing the address) was damaged beyond repair. Since the company that originally made the signs no longer exists, I’ve made an attempt to create a sustainable solution using PETG filament. I believe PETG should be able to handle the suns UV rays and general outdoor wear.

I’ve run into a bit of a snag in the software design. My prusa 3d printer has limited dimensions so I have to print two pieces and come up with a design that can easily connect the two, to look seemless. the depth of the sign is only 7mm. I want to sure it matches the original design. I tried to reuse someones lego (male / female) connectors, but that requires cutting some off the depth. if there are two pieces then each side requires 3.5mm, then the male connector still had to be cut, which caused the two pieces to easily fall apart.

Can someone suggest a good connector piece where there is a flat model and the two sides are only 3.5mm in depth? I’ve attached an image of the design.

mailbox-signage

Attaching another image of the original failed print. the original lego design had a male connector with too much depth so there’s a big gap. Generally looking for someone to provide a better connector solution than legos.

mailbox-signage-lego1

Hello,

Thank you for contacting us. A seamless solution is almost impossible when cutting models and certainly in this type of the model. I would advise you to look for another option to print a model as one piece in the material that is suited for outdoor usage and can withstand all possible weather conditions. Among our materials we would recommend you to check if polyamide with waterproof finish can meet your requirements, however we can’t guarantee long time durability of this material and finish.

Best regards,
Tetiana
Customer Support Engineer