Storage Rack for Small Parts Boxes

This is a flexible racking system for the Lockweiler 18x15cm small parts boxes. It can be built to any height, with any number of columns. It's designed to specifically store their Single Compartment, 7-compartment and 8-compartment boxes.

Planning

Each shelf is 39.6mm high. Each Binding Plate is 16mm high. For the construction in the photos, 1000mm Aluminium Extrusions were used. The total height of the plastic pieces is (24 shelves * 39.6mm) + (3 binding plates * 16mm) = 998.4mm.

I would also recommend using the Slicer estimates of filament usage to calculate the total amount of filament required for your racks. Mine used €140 in filament (9kg) alone. I used cheap PLA sold in 3kg spools. Use the “Prusament PLA” settings as normal, not the “Generic PLA” settings. I've never had good results with that profile. 

Rear Cross-braces are only recommended if your assembly will be side mounted, and not supported from the bottom. 

Items to Purchase

• 2020 Aluminium Profile for the verticals
  • I used these
  • This amazon listing also includes M5 nuts to use with the profile
• M5x20 machine screws for the binding plates
• M5x8 machine screws for the cross-braces (if required)

Printing Instructions

MAKE SURE you print 1 shelf first, and that it fits your aluminium profile snugly before printing all other parts. The source model has been included in case you need to make edits. 

I printed with 0.3mm layer height for speed. I had bed adhesion issues with the Prusa 0.3mm profile, so I used the Prusa "0.2mm SPEED" profile, and changed the layer height to 0.3mm.

Print the binding plates with solid vertical walls, so about 10 perimeters. The binding plates are the source of strength for the whole construction, so must not crack when the screws are tightened down. 

You must have at least a top & bottom binding plate. A 3rd binding plate is recommended for side-mounted racks or tall racks, like 1 meter tall (pictured). 

Single-Column Rack

For each binding plate, print: 

• binding_plate_single_base x1
• binding_plate_single_lid x1
• binding_plate_filler x1

For each shelf, print:

• shelf_left x1
• shelf_right x1

Two-Column Rack

For each binding plate, print: 

• binding_plate_multi_side_base x2
• binding_plate_multi_side_lid x2
• binding_plate_filler x2

For each shelf, print:

• shelf_left x1
• shelf_right x1
• shelf_centre x1

More Than Two-Column Rack

Print everything for the Two-Column Rack above, plus the following items for EACH EXTRA COLUMN in your construction:

For each extra column and each binding plate, print:

• binding_plate_multi_centre_base x1
• binding_plate_multi_centre_lid x1
• binding_plate_filler x1

For each extra column and each shelf, print:

• shelf_centre x1

Assembly Instructions

Assemble as per the images. Wipe down the aluminium profiles with some vegetable oil before sliding on each of the shelves. It goes much smoother with that. 

Each time you are tightening a layer of binding plates to the aluminium profiles, or the binding plates to each other, make sure the construction sits flat on a flat surface. You may need to loosen the screws, press it flat and re-tighten if the structure warps.