Sturdier 3-D Case Redesign

I already have a well-tested 3-D printable case for my tabletop RPG, but two pain points remain before I can release it to the community: the hinged spine needs to flex more smoothly, and the broad faces of each side panel feel too thin for repeated game-night handling.

Here’s what I need from you:

• Re-engineer the existing, book-style hinge so it opens a full 180° without stressing layer lines. Whether you widen the knuckles, introduce a living-hinge segment, or swap in an interlocking barrel is up to you—as long as the final solution prints reliably on a standard FDM printer and stays flush when closed. I do not want to use any hardware.
• Thicken the outer faces of both panel halves just enough to boost rigidity while keeping overall wall weight reasonable. Internal dimensions must still hold my modular ability/gear tiles and a sleeved character card. Interior dimensions of tile and card wells is perfect and I need those to stay the same.
• Also, need the raised graphic on the front panel removed as it does not print well - leave both panels flat on the outside.
• Supply updated source files (STEP or Fusion 360 archive) plus export-ready STL parts. I’ll verify by printing them on an Ender-3 in PLA; the case should open and close ten times without audible cracking and lie flat on the table when open.

If you’re comfortable iterating quickly and understand print-oriented design constraints—fillet radii, layer orientation, clearance tolerances—let’s fine-tune this case together so it’s convention-table tough.