This isnt my file -it’s from this category. i just thought I would post the size I had to reduce it to to get it to fit in my honeycomb and maybe others could do the same and we could see just how wide the variance is on these trays. It’s 1.071 x1.071". I had to do one square because when I tried to do 2 they didnt resize identically. the second one is off to the right - it’s bigger.
I don’t know what variance there may have been recently in the breadcrumb trays themselves. Certainly a possibility.
There are a couple of other possibilities though. Sometimes there’s a mismatch between the pixel resolution of your file and the pixel resolution that Glowforge expects. This is a common problem for Affinity Designer users. Make sure to export the file at 96 DPI, not 72 DPI. Check the width of the object in the Glowforge editor to see if it matches what you think it is
Also I find that newly cut pins are indeed difficult to get into the holes because they haven’t worn down yet. They’ll be looser once they get broken in a bit.
It’s not just this file. I have tried at least 5 files of pins and all of them have been too big for my crumb tray.
Same with mine. I’ve rendered a lot of pins unuseable trying to get them in or out. Thanks for the revised style.
I have two crumb trays, the one that came with my laser, and another I bought from the “spare parts” section of the Glowforge Shop. They have massively different size honeycomb openings. Any holddown pins that fit one will not fit the other.
it does seem a quality control issue
My honeycomb tray has holes that are smaller than many of the bed pins that I have tried. Thank you for this file!
I keep a tool by my glowforge that is sort of shaped like a screw driver, but doesn’t have the tip. It is the right size to round out any honeycomb holes that are too small or not at the right angle for a pin.
It’s not quality control - GF doesn’t manufacture these and the honeycomb is just a standard a material with no real specifications that affect the use of the machine. You just need to be comfortable creating your own files and scaling them appropriately.
I think it is quality control if the same manufacturer markets them as the same product but they don’t have the same size honeycomb
I’m sorry but the original 
has been in production for over seven years now and that’s just not how manufacturing works. Components change with availability and as long as they meet design specifications there is not a QC problem. I’d lay odds that the stepper motors in your unit are not from the same factory as in mine as well as several other commodity components.
The honeycomb is most likely spected for thickness but not grid size or grid size with a reasonable ± .
Some changes are just availability and some are incremental improvements like the black cable to the lid (a custom part) is now longer than it was originally.
Case in-point, back at the start the higher-end models had “upgraded stepper motors” to give better performance, but the reality was that most machines had the same ones. It’s cheaper and easier to use the same components across all models.
As mark stated, the spacing on the honeycomb is irrelevant to machine specifications. It was never intended to be used to hold down the material. That’s as important as the change they made to the design pattern printed on the lid a while back…