Ultimate box generator

Ultimate box generator

A parametric hinged box that prints flat in one go, with no hardware. The case is two matching open shells (base and lid) joined by a multi-knuckle print-in-place hinge, plus an optional separately hinged snap latch. Everything prints on its floor with the lid open flat, then folds shut.

At the default settings the closed case is 100 x 65 x 44.5 mm outside, and the print layout (base, lid and latch laid out flat) is about 100 x 182 x 27 mm. The result is three separate watertight bodies: base, lid and latch.

How it works

• Shells: base and lid are identical open trays with rounded corners and flat floors. An optional set of internal dividers can split the base into compartments.
• Hinge: fixed knuckles on the base alternate with moving knuckles on the lid. With fullPin on, one continuous shaft runs through the moving knuckles (teardrop bores keep it printable). With it off, opposed conical journals and sockets hold the lid instead. taperHinge trims the hinge supports to 45° ramps so nothing needs support material and the interior stays clean.
• Latch: with latchOn, a flat-printed handle pivots on the front of the base. Two tapered spring fingers snap over a catch on the lid, and separate rigid tongues locate the lid so the fingers only retain it.
• Preview: foldAngle and latchAngle pose the model. Print at 0 and 0, then to close the box set foldAngle to 180 first, and rotate the latch to 90 afterwards.

Parameters

Box size

• caseWidth (70–160 mm): outside width along the hinge axis.
• caseDepth (40–90 mm): outside front-to-back depth of each half.
• halfHeight (12–40 mm): depth of each shell. Closed height is twice this plus seamGap.

Structure

• wallGauge (1.6–3.2 mm): wall thickness. Use multiples of your extrusion width.
• floorGauge (1.6–3.2 mm): floor thickness of both shells.
• caseCorner (4–10 mm): outside corner radius.

Fits

• seamGap (0.3–0.8 mm): axial gap between the rims when closed.

Hinge

• hingePairs (1–4): number of moving knuckles. More pairs shorten the unsupported pin span.
• barrelRadius (3.5–5.5 mm): outer radius of each hinge crown.
• journalClearance (0.25–0.5 mm): gap normal to each 45° cone journal. Tune to your printer.
• knuckleEndGap (0.3–0.7 mm): gap between adjacent knuckle end faces.
• fullPin and taperHinge: switch between a continuous pin and conical journals, and trim the supports to 45° ramps.
• pinDiameter (3–5.8 mm) and pinClearance (0.25–0.5 mm): size of the continuous pin and its radial gap.

Latch

• latchOn: adds or removes the latch.
• latchWidth (22–32 mm), latchThickness (4–6 mm): handle size.
• latchBite (0.2–0.5 mm): snap overlap per finger. This sets entry and release force.
• latchClearance (0.2–0.5 mm), latchSeatClearance (0.1–0.3 mm): axial and locating fits.
• latchGripReach (1–4 mm) and latchSpringRoot (2–3 mm): finger ledge and spring finger width.

Organizer and preview

• dividerCount (0–4): internal dividers in the base.
• foldAngle (0–180°), latchAngle (0–90°): pose for viewing. Keep both at 0 to print.
• Readouts show the closed height, the internal width and depth, the pin span and the print footprint.

Printing

Print with foldAngle 0 and latchAngle 0 so everything lies flat on the bed. Keep the wall and floor at multiples of your extrusion width, and tune the three clearances (journal, pin and latch) to your printer; if the hinge or latch is stuck after printing, increase them slightly. Check the printDepth readout against your bed, since the latch adds to the footprint.