Bens Better Boxes for screws and other storage

I wanted a better box for storing screws! And I'm really pleased with this set - the result of a somewhat obsessive design process -  they are great for screws but also useful for all sorts of other things as well.

When you buy screws here you get handy cardboard boxes with a pull-down flap that can be left part-open for easy access. A great idea but the implementation is not quite right  - the door always pops out too far and gets crumpled and then your screws fall on the floor..  

I wanted to make one that works properly:

• door flap that has a ‘stop’ so it can't fall completely open
• thumb recess on lid for one-handed opening
• a latch so you can snap it securely closed
• easier to close than to open for secure transport
• minimal filament used - you'll want about 20 of these boxes
• no supports needed 
• smooth areas on door for labelling contents
• mounting holes for tiny cable tie, and locating groove, to hold sample screw in place 
• filament used for a hinge - no hardware required
• easy printing using normal cheap PLA
• a range of sizes to cover small and large screws

I've ended up with 2 variants, in various sizes. 

1.  the BetterBox -  really tough, but uses more material. 
   
   Small 5cm x 4cm x 6cm: 35g of filament 
   Medium 7cm x 6 cm x 9cm: 68g
   Large 8cm x 6cm x 11cm: 98g (use brim)
    
2.  the BracedBetterBox - almost as strong, but about 25% less filament used - you can print 35 small, 19 medium, or 13 large from a 1kg roll of filament!
   
   Small: only 28g of filament !
   Medium: 51g
   Large: 75g  (use brim)
   XL 10cm x 7cm x14cm: 110g (use brim)
   XXL 14cm x 9.5cm x 17cm: 183g (use brim)

PRINTING & ASSEMBLY

Print the box vertically, sitting on its base, with no supports. Print its lid face down, again no supports.  

I have printed many of them both on a ‘speed’ setting and a ‘structural’ setting. Structural is lovely, but if you're in a hurry then Speed actually seems OK. 

On my MK4S it is great at 0.25 layer height really well. I have used various PLAs both cheap and expensive and all are fine. I'd use a 'plus" type if possible , for toughness.

If the inside gets stringy, the door wont close smoothly so turn your printing temp down 5C. If you have problems with warping, especially with the larger boxes, you should add a brim.

There are some tiny little bevels and unexpected recesses that allow the support-free printing, in case you're looking at your box door and wondering why its shaped like that.

To assemble, squeeze the wings of the lid in a little and push it into place. Push in a length of filament to be a hinge  - push it almost all the way in , cut it off, then push the cut end flush. If it is hard to get in, clear the  hinge holes with something sharp like a pen or drill bit.