Beginner's Questions on Proper .STL Design

[BoozeKashi]

No problem, good luck, sounds like you are well on your way already. The kind of very shallow horizontal overhangs you are talking about can be handled by most printers that have any decent bridging capability. 300 micron with another layer right below it to build on is less than a typical layer width so it should not present much of a problem at all.

[Jeff B]

BoozeKashi - a friend of mine was good enough to print out some samples for me to look at, at 200, 160 and 100 micron Z resolutions, that have some of the kinds of shallow, unsupported horizontal insets I need to do. Better than I would have guessed. I'm feeling much more optimistic about this now.
Thanks again for your input!