System 58: Configurable/Parametric Boxes/Inserts with many Sizes; FreeCAD

This is part of the System 58 collection of boxes. They are designed as inserts with non-standard sizes, but can also be used as stand-alone boxes with or without lids.

Other parts of the System 58 collection:
https://www.printables.com/@konrad_2520545/collections/3048692

I included the FreeCAD (version 1.0.2) design file as well as a complete export of the many sizes that the design supports.

The standard base size of the System 58 insert boxes is 58×58mm with a height of 30mm (plus 1mm for the lid). The standard boxes are dark grey with black lids in the pictures. 

The sizes configurable (for width/length) in the design are multiples of that standard size.

Configurable Factors:

Every combination of those sizes exists as a STL, or can be generated using FreeCAD (see below).

Printing

I included two GCode examples for MK4S with a HF0.4 nozzle. However, you will probably want to print from the STLs or the FreeCAD design.

Load the STLs of the box size you want and the corresponding lid size into your slicer. Print the box exactly as is, standing up. Print the lid with the flat size down - you will usually have to turn it around 180 degrees. No supports are needed, you can use standard settings of your slicer.

Any material should be fine. If you want the boxes to survive direct sunlight in the summer you may want to chose a material that can withstand higher temperatures, like PETG or PC.

FreeCAD Design

I included the design file. The design contains just two bodies: the box and the lid. It uses a spreadsheet and configurable properties to change the size of both.

Open the design in FreeCAD 1.0.2 and select the Box:

You will see a "Config" section in the "Data" tab of that body where you can select the size for the X and Y directions

Clicking on the config option gives you the options listed in the table above:

Once you acknowledge the change, the sizes of the design will change for both bodies - the Lid references the Box design to match its size.

You can then export the bodies as normal, click each one, go to File->Export, select your desired file format and file name and then Save.

If you want to add or change sizes open the Spreadsheet and add more lines:

• Column A should contain a name that you can chose in the Box properties

• Column B should contain the size in mm (or inches or whatever unit you prefer)

• Columns C and D should simply reference A and B (e.g. C9 should contain "=A9", D9 should contain "=B9")

You will then be able to select your new sizes from the configuration.

The height of the Box is defined in "Pad Outer Box".  I tried to name each feature, so that it is easier to find it and change it if you desire.