Husky Roof Rack

The Husky Roof Rack is a modular, 3D-printed system designed to make transporting heavy items on top of Husky toolboxes easier and safer. It features seven 3D-printed supports and four custom TPU grips that connect with PVC pipes and screws. The rack provides lift points for carrying and lifting the toolbox, while the flexible handles increase comfort and reduce strain.

Our objective was to design a strong, practical, and customizable carrying system for items on top of Husky toolboxes. After the first iteration, we were asked to improve the design by making it stronger and easier to lift. It was important to create a design that was durable, effective, and simple.

In our original design, we began with a simple two-part attachment to secure printers to the top of a Husky rollable box for easy transport. The initial setup consisted of four corner pieces, three middle connectors, and three PVC top rails joined by screws.

After consistent use for over five months, we were asked to make the design stronger because there were weak points where PVC connections and screws reduced overall stability. We decided to redesign the supports to increase strength and reduce part count.

To improve the original, we combined the bottom and connector parts into a single 3D-printed side support. This removed the need for PVC joiners and screws from the original supports, improving both rigidity and ease of assembly. 

For the corners, we took the new combined side support and modified it until we created a single-piece corner that allows pipes to pass through and be secured firmly. We reinforced the corners using multiple fillets and strategic extrusions.

For the handles, we measured the PVC diameter and user grip width to design ergonomic TPU handles. To ensure a secure fit, we created a lofted inner chamber starting at 0.84” and tapering by 0.1” at the end. We also added a knurled texture using a helix-based swept cut pattern for better grip and leverage.

For the final assembly, we printed:

• 2 left-sided corners (PLA 1mm nozzle)
• 2 right-sided corners
• 3 side supports
• 4 handles (TPU)

PVC pipes were inserted through the supports, fastened with screws, and topped with the handles. This modular system can be easily disassembled and reattached when needed.

The final design produced a noticeable improvement in strength, rigidity, and durability. It is able to handle the load placed upon it on a weekly basis with no signs of wear. Additionally, the new design is very easy to assemble and much easier to use.

In future iterations, we would like to experiment with stronger filaments such as PETG or carbon-fiber PLA and continue improving upon the current design by maximizing filament efficiency and further strengthening the structure based on future feedback.

However, when printing, we had an issue with one of the corners, as it had ended up being too weak, meaning the printing side is crucial. When printing, print on the side that has the handle, or the hole on the side opposite the corner.