Be sure to recalibrate your printer (or at least reconfirm calibration) right before the print, and you should be fine w.r.t. sizing.
The majority of my models are scaled @ 1/96, (within the slicer) which is large enough to see small details but not so large the boats can't be transported inside a vehicle - like a 6' Trident boat.
As for printer calibration, that has never been an issue unless I make any hardware changes. (I'm using industrial printers.)
I was able to round the curved edges with a pair of edge selections and a fillet command using Fusion 360. (It took longer to type the first two sentences in this thread than complete the task!)
This app seems to have incorporated a lot of similar time-saving features across the board and being free, I can learn and upgrade to a more functional paid version later (I don't need to create tool paths or have team collaboration capability). I have no issue paying for upgrades to support a program/company, but the current situation has remained static for too long for me to wait anymore.
I can import the CAD output into LW for texturing/animation when required. I enjoy LW's interface, but for modeling efficiency, (= time-savings!!) it isn't even close.
It is not possible to change your mind and move the hole in that cylinder example with any mesh modeler (unless the modeler is storing part data in the background). We've always been better off with a true CAD tool for industrial design (aka "hard surface modeling" in wannabe mesh modelers). Even LW employees shared this decades ago: https://forums.newtek.com/threads/rhino-and-lightwave.9577/
I appreciate your demonstration but when you acknowledge "setup is none destructive", you are recognizing that "the modeler is storing part data in the background"...as I stated.
I was really just trying to promote the idea of having a real CAD app in our toolboxes, as I believe you have done with previous mentions of DesignSpark (and others have suggested FreeCAD, MoI, & Fusion 360). Modern mesh modelers (like Blender) are making great progress in non-destructive techniques but they are still far from delivering what CAD tools can offer. I'm hoping the line continues to blur so we don't need to be jumping between applications.