Rectangular Crescent shaped hinged box

thingiverse

This is a hinged case design based on a rounded rectangular prism (superellipse or Squircle https://en.wikipedia.org/wiki/Squircle) that's been transformed into a crescent shape through inversion on a sphere (https://en.wikipedia.org/wiki/Inversion_in_a_sphere). The design was then sliced and lips were added along with hinges. Internal ribs to enhance printing quality were also included. Holes were drilled for a latch. Latch hardware and accessories were created and integrated. Note that a PS4 DualShock 4 controller fits perfectly inside the case. I printed the case out of PLA, but I've successfully printed similar items using PETG without any major issues. Build instructions: If you want to try making a box with this type of hinge before committing to this large print, check out https://www.thingiverse.com/thing:3407459. That project and this one share the same hinge arms. The files here use a 1.81 mm hole that has worked well with multiple filaments. Print each of the following STL files: * blob40_1_hinge_screw_bot.stl - Requires support material, print with curve up, took approximately 20 hours to print on a Prusa i3 Mk2 w/ 0.4mm nozzle and 0.2 mm layers. * blob40_1_hinge_screw_top.stl - Requires support material, print with curve up * arm_set.stl * blob40_1_knob.stl * bottomPlate.stl * topPlate.stl Assemble the hinges See https://www.thingiverse.com/thing:3407459 for a close-up of the hinge pieces and how they fit together. Try pushing a long piece of 1.75 mm filament through all of the hinge holes first to ensure they're not clogged up. Use 1.75 mm filament for the hinge pins and hold them in place by flattening the ends with a soldering iron separated from the plastic with aluminum foil. Some foil may stick, but it doesn't matter and can be easily trimmed. Attach the latch hardware using 6 1/4" 4-40 screws and nuts or M3 screws.