Playing card travel box

There are so many card boxes out there… But none could do all I wanted.

Let me show you its features:

• The box
  • Actually protects the cards for travels - no holes and fairly strong
  • Fits a stack of gold plated or similarly rough plastic poker cards - They are thicker than usual
  • Both single and double deck options available
  • Easy to print
  • Low profile
  • Just the right amount of card space for easy handling
• Lid
  • Is reversible - tuck away when open and you wont lose it
  • Stays closed and does not fall/open on its own - press the sides to release
  • Easy to open and close
  • No sharp corners
  • Dual color logo - if you want to try a fancy color swap

DIMENSIONS:

• My cards are:
  • 57.4mm x 87.2mm
  • stack height 18.9mm
  • 3mm corner fillet
• Box has large tolerances to fit the cards comfortably:
  • 1mm on every side (89.2 x 59.4)
  • 1.5mm on top (20.4)
• Wall thickness is 1.2mm (three line widths with 0.4 nozzle)
• Overall outside dimensions are:
  • Single stack
    • 64.8 x 94.6 x 22.8mm
  • Double stack
    • 125.5 x 94.6 x 22.8mm

ABS (100% infill)

• About 31g of filament for single stack 
• About 39g of filament for double stack

HOW TO PRINT:

Be aware that every material behaves differently and every printer has different tolerances.

For me alone the difference between white and black ABS made an impact on the friction! (both work fine but feel different)

Want to print instantly without anything fancy?

• Pick a model with “SET” in the name, they contain both halves (either with or without logo engraved in the lid)

Want to print each half separately?

• Pick one “LID” model and one “BODY” model of the same stack version
  • Lid versions differ by logo engraving
  • Body versions differs by slight change of the detent pin - tighter or looser fit
    • I prefer tighter for the single version and looser for the double version as that one cannot be squeezed
    • You can always sand it to your liking

Want to make a dual color print on a single layer with a single extruder?

We will trick the printer into thinking it has two extruders and simply color swap manually after the logo is printed. This tutorial expects you already know how to do a manual color swap (Pause, Unload, Load, Unpause)

Here is how its done! (Prusa slicer and similar)

1. Insert the logo and the lid into your slicer
   • Make sure they align correctly
     • Single stack version is not centered, align it by hand or use the version with an alignment frame, which centers it by default at the cost of printing a skirt.
     • Double stack version is centered
   • Make sure you move both of them at once to keep the alignment
2. You can also add the body into your slicer, if you wish to print everything in one go
3. Order them so that the logo prints first, then the lid, then the body
4. Go to Printer settings > Extruders > change to 2
5. If you like, go to each extruder settings and change their color for easier identification
   • Printer Settings > Extruder 2 > Extruder color
6. Go to Printer settings > custom G code > tool change and insert the same G code that you use for color swap (for example M600)
7. Now you can assign each object their extruder
   • 
   • I was forced to use the second extruder on the box, otherwise it printed the box first and not the logo
8. Check the first layer g code progression carefully 
   • The logo should print first, then the rest
   • Check that there is only a single color change g code in the code
   • If you start by printing another objects first layer, you will have to do TWO color swaps.
9. Additional tips:
   • Check your first layer and other XY scaling - it may affect how well the logo blends
     • I suggest very low values or disabling
   • You may want to try adding modifiers to the logo or the box
     • For example i printed the logo with concentric bottom infill and the rest with monotonic
     • I also tried a larger extrusion multiplier just for the logo
10. Send it to your printer as usually as when it pauses, switch the filaments, and unpause, then the rest of the box will be printed.

Enjoy!

As usually, if you want, feel free to request a size or whatever. Maybe I'll do it.