Entire joint length is about 1" (1.02 or something). The fingers are about 0.035" wide. I think I could probably take them down to about 0.02". I tried at closer to 0.015, and it scorched to death.
Manually rounded corners with sandpaper, sanded to 600 grit, then hit with a coat of Feed-n-wax. I like the look, I think I will incorporate it in my next project.
Looks nice, would make a great look on a box, right now as it sits looks like a tiny book, You should get a shot of it being held by a lego character, that would make my day LOL.
If you really want to go thinner you could try creating the cut in three layers. The first layer would be the left side of the finger, the second would be the right, and the third would be the bottom.
In theory it would allow some cooling between cuts. It seems scorching gets worse as your cuts get closer. This might give you just a bit more tolerance.