Let me introduce myself, my name is Martin, a student on Solidworks.
At the moment I'm interested in splitting by a surface, and molding but I'm asking myself a question because I do 3D printing and obviously, two parts obtained by a cut and which fit together have a set of zero on Solidworks and therefore it won't be possible as soon as they fit together. How can I change this? sometimes I manage with material removals... But sometimes it's too complex:( I can't.
For example, this cut made with a surface attached.
For my part; When I make a design where I have to create parts that fit together, I put a set of 2 tenths of a turn directly into the design via a shift of the sketches. It saves me from having to take everything from behind.
Personally, for a 3D print, I see a design error that will be more problematic from the point of view of "precision and fit of the interlocking"; the tips of the teeth! They must be flattened (or rounded) leaving the gaps as they are (in points). And technically, it could even eliminate the need for a compensation game that with such small teeth, would make them really very thin.