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The above PDF and the previous research into the tightening torques for the series connections (Electrical Contact Resistance for Module to Module Series Connections ), as well as the recommended tightening torque for our EV200HAANA contactors (8.8 - 11Nm of M8 nut for 500A rating), leads me spec a tightening torque of 8Nm for these joints, which can safely be reached by the 100% infill regular heat set inserts and greatly simplify the manufacturing process. Care should be taken to not tighten the bolts when the plastic is cold, as the plastic is brittle in cold temperatures. We may print the parts from Polycarbonate instead of PETG for the final version.
This was a less intensive research / torque specification process than I would have liked to do (ideally do the tests with other epoxy, get molded in inserts, test with polycarbonate, and test the actual electrical contact resistance) but it should be good enough. I don’t foresee major issues with this as long as all the proper procedures are followed during manufacturing/assembly/maintenance.