Interlocking Card Tray - v2

thingiverse

As this model diverges from the original more substantially, I decided to release v2 of it to maintain separation. Key changes from the original model include a customizable horizontal and vertical interlock system. I'll eventually fine-tune this one to allow configurable finger access dimensions, but for now these trays function well as they are. The top/bottom interlocking feature enables stacking the trays when not in use. By halting the print process at 2mm, you will obtain a component that fits on top. You can then wrap elastic bands around the interlock system to keep everything organized when not in use. I've made an effort to comment the code thoroughly to aid my own maintenance of it, provide insight into how it works for beginners, and allow experienced coders to adopt any part they want. I should also attribute the fillet formula used, which I didn't create myself. I think I obtained it from an OpenSCAD forum. Print Settings Printer: e3d Bigbox Rafts: No Supports: No Resolution: 0.25mm Infill: 100% Notes: I'm printing with a 0.4mm nozzle, and all prints shown are made of PLA. To test the fit of the trays, I recommend using the customizer to design a small square shape for, say, 10 cards as your first test. Print two and examine the fit in relation to how they interlock, both stacked on top of each other and side by side and end to end. If they're too loose, then adjust the sideInterlock distance upward (max is really 2-nozzle thickness, but that assumes a perfectly accurate printer that produces perfect pointed corners). I find 1.1 to be a pretty tight fit. Zero would mean no interlock at all. So if you find the fit is too tight, adjust downward. One other point to consider is that the design presumes all cards are flawless and pristine. Over time, well-used cards, particularly those without sleeves, tend to occupy more vertical space. The larger the deck, the more this will be noticed; so for Dominion, with a large deck of copper, the problem becomes fairly significant. You can either sleeve your cards, which itself requires you to enter larger dimensions for both the cards and the thickness, or add a little to the width you specify for cards. Adding, say, 20%, to the card width should suffice for a long time.