Improved Parametric Rugged Box

Improved version of @TheSameNameTwice boxes (https://www.printables.com/model/56071-parametric-rugged-box).
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updated June 30, 2024

Description

PDF

Improved version of PARAMETRIC rugged box.

Some specific versions: 
[AA Batteries here: https://www.printables.com/model/903125-improved-aa-battery-rugged-box ]
[AAA Batteries here: https://www.printables.com/model/903130-improved-aaa-battery-rugged-box }
[CR123a version here: https://www.printables.com/model/903148-improved-cr123a-battery-rugged-box ]

Liked the design from @TheSameNameTwice, so I remixed it improving and reducing some weak points.

1. Top cover improved closing latch:

The lever is now longer, to have a smoother closure and more durability. 

2. Bottom box has three improvements:
  • The hinge is now supported by two smooth inserts coming from the bottom, increasing durability and avoiding breaking it during first assembly.
  • Additionally I carved a V shape insert to have a better hinge snap-in during assembly.
  • Finally the front latching area is now improved a little because it was too thin in the original model.

Printed with tree supports to improve plastic structure but they may be not used.

Suggested a flexible material like PETG to ensure a better assembly of the hinge.
Bottom box can be printed in PLA, but cover is recommended in PETG.
 

Fusion 360 Parameters, some suggestions

All dimensions are INTERNAL, except for the corners which are smoothed out.

Split between top and bottom height (height ratio) can be adjusted from 0.25 to 0.33 or more if make sense.

Corners can be smoothed with different radius, standard is 4, but you can go from 3 to 10 or more if dimensions permits that.

 

 



Other general suggestions to create parametric STL.

  • Start Small like 45x45x35mm (l,w,h) then expand
  • Expand in small increments if something turns out wrong, F360 does not like incrementing this model on big steps
  • Don't go too big, or the latch will not be able to retain closure, keep len+wid below 200mm
  • If you get error on latch smoothing, simply put length to 45mm and then again to 55 or more.

You can always fix the fusion model afterwards, and revert to the original after modifications are done.
 

Printing
Use predefined STL in folders.

- or -

Edit Fusion 360 model with: 

  • Modify → fx Change Parameters → Parameter dialog
  • Select bottom or top
  • Right click → Save As Mesh…
  • Download or save .STL 

Finally open the .STL in slicer and print.

 

Assembling:

Step1: Print bottom and top

Step2: Assemble the top cover on the bottom by pushing vertically down

Some .STL samples in download section.
I'm adding some of them now and then.

 

Tags



Model origin

The author remixed this model.

Differences of the remix compared to the original

Improved sturdiness of hinge, and latch.
General updates to F3d model.

License