I see. So it’s not the size of the circle on the round hole that’s the issue, it’s how tight the “sandwich” is, which would be sensitive to material thickness. So on @jestelle’s design, that would be the spacing of these holes,
(Though @jestelle has a slightly different hinge — 6 on the bottom and 4 on top — b,t,b,t,b,b,t,b,t,b)
Thanks for sharing your experience. I haven’t designed any hinges like this but good to learn the pitfalls ahead of time!