Harbor Freight Storehouse Boxes... overthought

This is yet another box design for use with Harbor Freight Storehouse storage cases. These models went through several (too many) iterations before settling on this one and this package does include the original “Big Foot” version and then the later “Small Foot” version. The latter works better for the half-height stackable variants. The key features of the design are:

• Separate, press-fit feet
• Snap in (and out) label tags
• Stackable half-height versions

The separate feet allow the box to be printed in the “proper” bottom-down orientation, avoiding the overhang mess of other orientations. (I had thought this was a unique idea until I saw a couple of other models on here doing it but… the more the merrier!).

As for the labels, I noticed that many remixed designs were made to include some kind of built-in label. I wanted to allow for labels, but be as flexible and as unobtrusive as possible. So I hit upon the idea of cutting small slots in the upper corners of the boxes and making flat, “springy” labels that can snap in. The labels are flat so printing them is easy. Also, they are provided in several different lengths for different orientations in the box. For those who do not want to use the labels, the slots take up no extra space and do not affect the boxes, while maintaining the option of adding the labels later.

The half-height feature was a bit of an afterthought motivated by the need to storage a large variety of very small items that may not fill a full box or even a divided box. Making them stackable necessitated two design changes:

• The smaller, chamfered round feet allow the top box to sit inside the lip of the bottom box. The other box variants were redesigned to accept the smaller feet for consistency.
• Adding the groove around the divider keeps the top box from see-sawing on the bottom box. I think it makes for an even nicer fit and I like the aesthetic as well. (In hindsight, it could have been made by simply creating a half size box and combining two of those bodies.)

The original HF boxes are slightly sloped, perhaps to aid in the injection molding process. I measured the top and bottom and initially went with a straight side using the longer, top dimensions, but it became apparent this resulted in a rather tight fit, further exacerbated by the grip of the 3D layer lines. I changed to the average of the bottom and top measurements: 53.5 mm * 38.5 mm. I am using a wall thickness of 1.25 mm and an outer fillet radius of 4 mm. BTW, the ratio of the long dimension to the short is very close to √2, like A-series paper.

Caveats:

• Depending on your printer the quality of press fit of the foot pins into the box sockets can vary. Outside of remixing to tweak the sizes, some other things to try are:
  • If the fit is too snug, consider nibbling off a few bits from the foot pins with a flush cutter and/or reaming out the box socket with something like a drill bit. 
  • If the fit is too loose, try adding a very small drop of adhesive (e.g., acetone for PLA) to glue the foot in.
    
    The fit should be tight; the foot is not meant to be removable. I usually press the foot in on a hard surface with a satisfying crunch.
• The labels are meant to be removable but should not simply fall out. I have no idea how well they will fare over time with fingers dipping in and out to grab parts.
• As I said, the half-height versions were a bit of an afterthought. I tried to make a reasonable close fit, but they do not snap together. I don't know how well they will contain their contents with the case being shaken around and turned in all different orientations. I figure if the stock boxes keep their contents then these should as well.
• The snap-in label tags in the bottom box of a stack will interfere with the fit except when in the middle of the divided variant. Not sure what the best solution for this is. Lower slots could be added around the sides, but since the these are already half-height, that seems awkward.

I don't think infill matters on these since they are almost totally walls.

Try these out and let me know what you think.