Packing Blocks

Packing Blocks

This is a set of simple blocks with stiffening pockets to be scaled in the slicer to the size required for creating custom padding blocks for packaging, using spiral vase mode printing.

These models generate blocks that are both flexible yet reasonably crush proof in all three axes to protect vulnerable items in shipment. They consume relatively little filament and are a good way to use up nearly empty spools. Color swaps in mid print don't seem to affect strength. The blocks add little to package weight and print quickly.

There are three rectangular models, with proportions 1:1:1, 2:1:1 and 3:1:1. They have, respectively, one, two or three pockets on two opposite sides. Choose the appropriate model and scale it in the slicer to the necessary dimensions. Orient with the pockets on one of the vertical faces. If more complex models are needed, modifying these designs should still be quite simple. The basic concept doesn't require anything in the way of intricate detail.

I'm happy to create and add other models to this post by request through the comments.

Vase mode will leave the top end of printed objects open but that's not much of an issue. The round/oval pockets provide most of the strength. For certain proportions, the tops of the round/oval pockets don't close up completely. That doesn't really cause any problems either.

I've printed many of these, all in PLA, mostly with a 0.6 nozzle, though they would be fine with a 0.4 nozzle too. I typically specify three layers for the bottom surface to assure the bottom doesn't easily separate from the remainder when removing from the print bed.

Some of the images I've posted show some specialized blocks with extra custom pockets for a particular object. Those require modifying the designs included here or creating new ones but the basic rectangular models work for most situations. In one case (not shown) I was able to add a custom pocket to hold some small miscellaneous items that were to be included with the main object in the package.

I recommend printing about 3-4 degrees C hotter than normal for PLA to enhance layer adhesion. Add a brim for extremely tall blocks if they have a small footprint on the bed.

These should provide reasonable cushioning and protection for shipped items, barring the occasional drop from an airplane or dragging the package with a rope behind the delivery truck, as they sometimes seem to do.