System 58 Sorter Box: improved MINI Box

This box is part of the "System 58" storage box system. It is an improved version of the first mini box model that is easier to assemble.

On the outside it takes 180×128mm, 33mm high; on the inside the usable space is 174×116mm, 31mm high; or enough for 3×2 basic inserts.

"System 58" collection of compatible boxes and inserts: https://www.printables.com/@konrad_2520545/collections/3048692

Old model: https://www.printables.com/model/1523746-mini-sorting-box-system-58-printable-on-prusa-mini

Design

As one of the main goals the box is 180mm wide, 130mm deep and 33mm high  - meaning it just fits on the Prusa MINI print bed. It should also fit on most other small printers that have a bed of at least 180mm in width.

The box is compatible with most of the inserts listed in the "System 58" collection (see link above), so if you want to divide it into compartments - simply print some inserts.

The only extra materials needed are a few short pieces of filament and a few drops of super glue. See "Assembly" below.

Printing

PLA will usually be a fine material for those boxes. If you need them to be more heat tolerant (e.g. to be left in the sun) then you may want to switch to PETG or an even stronger material.

For the Prusa MINI or MK4S, with PLA: simply use the GCode files included.

Prusa Printers: open the PrusaSlicer 3mf project files - they already contain the correct settings - then select your printer and material. 

Printing from STL

The main box can be printed standing normally on the print bed without supports - all protruding features have chamfers to support printing.

The box lid should be overturned 180 degrees for printing. The front lock protrusion needs some support, the hinges at the back are designed to print without supports. Make sure you use supports from the print bed only, no internal supports - otherwise the hinges will be blocked.

The main box lock should be printed flat to the bed and needs no supports in this position.

I recommend to increase the number of solid layers and perimeters - the models print faster without infill.

Assembly

Print everything as described above. After removing the support from the lid you can connect the hinges with a few short pieces of filament and a drop of glue.

Start by removing the supports from the front of the lid. 

Then join the hinges on the back with a short piece of filament - the holes are designed to easily fit 1.75mm filament.

Cut the filament to fit tightly. Put a drop of superglue on the sides to fixate the filament in place. Important: do not glue the lid to the main box or to the filament - this would stop the hinges from turning. Two very small drops of glue on the side of the main box hinges will suffice. If you prefer you can also use a soldering iron to weld the filament to the hinges

Do the same with the locket in the front of the box.

License

I chose GPL deliberately: I want this design to remain free. Feel free to print as many as you like, feel free to sell your prints. But, if you give prints away or sell them include a link back to here or give the recipient the original design files; if you change the design or add features - please publish your "sources", a'ka CAD files under the same license.

The included CAD files of this design were made with FreeCAD 1.0.2. I tried to label all features to make it easy to understand what was intended. Send me a message if you have questions.