Modular storage system (0.8 nozzle, 1.2wall, vase mode optimized)

Most of the storage organizers, containers provide not very big storage capacity which is more suitable for small size parts like electronic parts. I did not find a storage system which would give a bigger storage capacity and could be printed fast enough with as low filament consumption as possible. So I decided to create it from scratch.

This modular storage system was optimized for printing in vase/spiral mode using 0.8mm or bigger nozzles. Printing in spiral mode was one of the main requirements for modeling due to its lower filament consumption and printing time. 1.2mm wall size was choosen as it appeared to be the minimum width providing satisfying toughness for such a tray/enclosure size. Printing 1.2mm single wall with 0.6mm or smaller nozzles did not give an acceptabe print quality. Both enclosures and trays designed for printing exactly 1.2mm walls in one pass in spiral mode. Different wall width will affect thresholds and functionality. Other parts can be printed with 0.8mm walls without any negative effect.

The result was achieved using printing parameter and other recomendations listed below:

1. Enclosures

Basic and wide enclosures have some sort of a back wall which can be used to mount enclosure on a wall. The model should be placed with a back wall on a printing plate. This way you have to ensure that slicer does not remove holes and openings when slicing the model. It is some sort of a combined mode when the program slices the bottom as in normal mode and other part of the model in spiral/vase mode. The problem is that not every slicer is capable to process it this way. I could achieve this with Cura 4.13.1 and PrusaSlicer 2.6.1. Recent version of Cura produces chaotic lines instead of side walls and I finally did not manage it to process the model correctly. Otherwise you can slice it without the bottom ("Bottom layers" is set to zero) or make it solid without any screw holes and opening ("Remove all holes" is On in "Mesh Fixes" setting). Solid bottom will certainly increase filament consumption.

I sliced it in Cura 4.13.1. It capable of slicing the bottom correctly with holes as designed. But as always there are also some delicate stuff:

• Important. In order to make Cura to slice 1.2mm wall for 0.8mm nozzle you have to set the wall size to 1.199mm. Otherwise Cura did not slice top most layers above tray guides.

Below are settings which I used in Cura 4.13.1 and gave me acceptable quality:

layer height = 0.2
wall thickness = 1.199
wall line count =1
z-seam alignment = user specified
z-seam position = back
seam corner preference = hide seam
top layers = 0
bottom layers = 8
initial layers = 8

Originally top bottom was designed to be 2mm thick (10 layers at 0.2 layer heght) to be enough for screw heads, but 1.6mm with 8 layers was also fine.

skin overlap percentage = 10%
infill = 0%
initial layer flow = 125%
inner walls flow = 98%
print speed = 50
wall speed = 40
top/bottom = 20
print acceleration = 200-300
print jerk = 4.0
remove all holes = off
spiralize outer contour = on
smooth spiralized contours = on
slicing tolerance = middle

I am not very familiar with Prusa slicer. But it certainly capable of slicing the bottom as I wanted it. When finding a solution with “combined” mode I was able to slice it in Prusa as well, 

but I had some strange width increase on the top end of side tray guides. Unfortunately I did have enough patience to find a way how to avoid this. Maybe some of you will find right settings and I would really appreciate if you share your ideas. To allow Prusa2.6.1 to print the bottom you need to set “Slicing mode” to "Regular" in advanced pritning parameters. Other parameters… no tricks.
 

2. Trays

Trays do not require use of specific Cura release. Basic tray was the first object to print due to its short nearly 1-hour printing time. Slicing was originally made in Cura 5.5.0, but I am sure it is possible to slice it in Cura 4.13.1 to not switch form one release to another. In older release you have to keep in mind and set the wall thickness to 1.199mm as well. 1.2mm for Cura 5.5.0 was fine without any tricks. There were only two things to remember:

• Tray bottom designed and should be 0.8mm thick. It is 4 layers (both bottom and initial bottom layers) at 0.2mm layer height. Otherwise there might be issues with tolerances with enclosure side guides. If to setup less than 4 layers there will be an issue with front wall overhang as the front wall starts exactly at 0.8mm height 
• Z-seam position should be set to "Back" if placing the tray handle to the plate front side. Otherwise I had strange line on the same side as for the seam. 

3. Dividers

The only thing to know is that all dividers should be 2mm thick. They are printed in normal mode . I would recommend printing them with 3 top/bottom layers 2-3x walls, with not less than 15% infill.

4. Connection bar

Connection bar printed optimized for vase mode as well with 2-3 bottom layers. Nozzle size line width 0.8mm and 0.2 layer height. I think that other layer height should also be fine.

I am totally not sure that it is possible to scale it. To avoid any tolerance or parts compatibility issues do not change any linear dimension.

I hope I did not miss anything and you will not meet with any other significant difficulties reproducing this storage system. It will be great if you find it good enough and useful for your purposes. Please feel free to contact me with any questions, issues or ideas.