FlexiBox

A modular, stackable and connectable box set

Hello! I'm new to CAD modeling, and this is my first "challenging" model that I've created from scratch.

I needed to organize various rooms in my house, but I wanted an elegant and smart solution. I found something suitable, but they didn't meet all my needs. I also aimed to save as much filament as possible without the need for foldability or excessive complexity in printing, all while ensuring reliability and robustness. This led me to design my own modular box, which I called FlexiBox.

Since I wanted to incorporate the Voronoi style, primarily to reduce the material used – considering how difficult it can be to print all these holes vertically – I decided to make the box entirely modular, using as few supports as possible. This way, I can also use different styles and colors to create a box.

The FlexiBox consists of 4 main parts:

• The corner.
• The side.
• The base (which doubles as the lid!).
• The extension.

The corner remains the same regardless of the dimensions you choose; you'll need 4 identical corners for a FlexiBox, which can be used interchangeably in any other FlexiBox.

The base is also the (optional) lid, while the extension has a double use (and can't be used with the lid):

• If you decide to keep the box open (without a lid), the extension is useful to cover the joint, making everything smooth.
• If you want a taller box with the extension, you can extend it as you like. Just print another full top part (corners + sides) and put it on the extension.

All the parts are interchangeable, and I've provided various options for composing the FlexiBox you prefer.

The possible dimensions are:

• 50x50mm
• 50x100mm
• 50x150mm
• 50x200mm
• 100x100mm
• 100x150mm
• 100x200mm
• 150x150mm
• 150x200mm
• 200x200mm

The boxes are stackable, and you can also mix Voronoi styles with solid ones for both bases/lids and sides.

And of course, you can use whichever colors you prefer for any component, creating stunning, colorful storage solutions.

Printing

Start by selecting the base size, then print 2x sides for each dimension and 4x corners.

If desired, print another base of the same dimensions to create a lid or add the extension to cover the joint or make it taller.

Filament: Use any rigid filament. I used PLA.

Resolution: Use 0.20mm. Smaller resolutions would break the tolerance of joints but hey! Feel free to share your feedback!

Support: Use supports only for corners and extensions. The base and sides don't require support. Refer to the pictures for the correct orientation.

Infill: 10% infill is sufficient, but consider using a little more for corners. If you plan to print those ≥150mm, I'd recommend increasing the infill a bit.

Note: For corners, please refer to the pictures for the correct orientation. It's better if the joints are on the upper side so the support won't affect the top side quality.

Tolerance: The snugness of parts was achieved after printing a ton of prototypes using only my printer. So, there's a chance that things might not work perfectly with other devices. I'd suggest starting with the smallest size (50x50mm) to ensure everything fits just right.

Assembly

It's simple! Each corner and side have interlocking joints that secure the top part.

I recommend assembling the entire top part first (sides + corners). Once that's ready, place it over the base and press down to interlock the parts.

Note: It's normal if putting only one side into the base makes the joint a bit loose. You need the complete top part to verify if it fits correctly into the base.

For the lid, you need another base, and you can use it on any side. It's a bit looser face-down, while face-up fits snugly.

If you want to keep it open or increase the height, add the extension where you can put another top part.

Connection

Finally, if you want to connect them, you need to print some joints and thicknesses. They are very tiny, so they should be an easy print. The joint is used to join the bases, but then you also need to add thicknesses to all the unjoined sides to balance the base.

I'm looking forward to hearing your feedback!

Changelog

22 Aug 2023:

• Included a decorated lid designed for 50x50 dimensions only (not suitable for use as a base)