@smellsofbikes Ok, when I'm back at the computer I'll model the lid dovetail separately instead of subtracting the base from the lid, and add a clearance parameter.
For fudging the visible edge, I'd consider getting a 40° internal angle, 20° per side cutter, to reduce the visible curve at the edge.
Another idea would be SLM or SLS now that it's relatively cheap. But... not in 316 stainless!