Interlocking Sorting Cups (Square Shape)

What is this

[Update3: A couple of more variants were added after recent user requests. 

1) Now there are models with a 1x3 and a 2x3 footprint including larger lids. They should work the same way as the other variants and should be fully compatible. However, I haven't tested them. Also, these are too large for the Prusa Mini. : (

2) You can now find all cup variants without the interlocks.]

[Update2: Another user request! ^_^ Added cups with a larger footprint (1x2 and 2x2). See the gallery or the pics posted by smartroad in the comments section to get an idea. Printing these will take quite some time, so I highly suggest to print the test models first to make sure you print the variant with the right clearance.]

[Update: As per user request I have added taller cups (+16mm and +32mm), in case more volume per cup is needed. See gallery for examples.]

These are sorting cups that can be easily connected to create trays of any size. This is a square shaped variant of my hexagonal sorting cups (version 2).

I usually use them to keep board game bits organized during play. The cups have a good size for most playing pieces, without wasting much table space. The connection is very tight and stable, so they can easily be passed around without worrying they might fall apart mid-air. Also, players can assemble their own little storage tray to keep everything organized in their play area during a game. Apart from board games they are quite useful for anything related to sorting or storing. They also make for a nice gift. The cups come in three different sizes.

In addition to the square cups, I designed cups with a triangular shape. If connected, they form a square cup with two compartments. This is pretty useful if you need to organize a lot of different small pieces without sacrificing too much table space. As with the square ones, the triangular cups com in three sizes as well.

The cups are stackable. This helps a lot during clean up after a gaming session and makes them storing them much easier. 

Also, they come with two types of snap-on lids that you can use to keep stuff from falling out. For both shapes there is a see-through variant as well a fully closed one (for very small objects).

How to assemble and disassemble

The cups have jigsaw-like connectors that snap into each other. The easiest way I found to connect/disconnect them goes like this:

• On a flat surface, place two cups next to each other, one of them slightly elevated, so that the connecting parts are touching and one connector is resting on top of the other. The upper brims of the cups will touch as well.
• Press down with your hand right where the brims are touchting until the cups are fully locked in. It might click and crack a little. Don't worry, they won't get damaged.
• For disassembly, press down on one cup and press up on the other until they separate. Sometimes wiggeling or slight twisting helps (No, I'm not talking about dancing but it won't hurt the process either).
• Do not try to “fold” two cups against each other. They will probably survive, but the connecting parts might get damaged at the edges, making the connection less tight and less stable.

How to print

I mainly print with Prusament PLA or DasFilament PLA, using the standard Prusament PLA profile in PrusaSlicer. If the print dimensions are accurate, the connection is tight enough to make them hold together quite strongly, but still loose enough to make separating them an easy process. However, if your printer is not correctly calibrated or your filament diameter is not consistent, you might end up with connectors that are too big or too small.

In the file section you will find several different models: 1x1 squares, 1x2 rectangles, 2x2 squares and triangles, each in three sizes (20 mm, 36 mm, 52 mm). For every type of model theres are 5 STL variants, each with a slightly different clearance between the connector parts (between 0 mm and 0.2 mm). In addition, there are 5 corresponding test models with the same difference in the clearance. 

To find out which clearance works best for your printer/filament, follow this process:

• Print all test models: 5 female clearance variants (0.00 | 0.05 | 0.10 | 0.15 | 0.20) + at least 1 male part.
• Try fitting each clearance variant into its counterpart:
  • Do they slide into each other without using much force? → The clearance is too big.
  • Do you need a lot of force to make them fit or don't they fit at all? → The clearance is too small.
  • Do you need some force until they click into each other? → This is the clearance you need. A good rule of thumb is this: Using your thumb (Ha! ^_^) and index finger, if you need both hands to make them click into each other, you are in a good spot. If in doubt, go for the tighter fit.
  • If none of the test prints work for you, try another filament or calibrate your printer's extrusion rate. Then print the test models again.

In most cases you should be able to pick the right variant without having to recalibrate your printer. Print 2 or 3 cups with the gap width chosen above and test if they fit well. Personally, I tend to go for a pretty tight fit. I hate wobble and I also got the feeling that prints seem to have shrunk very slightly after a couple of days, making the connection a bit looser. For me, the required clearance varies between 0 and 0.1 mm, depending on the filament.

If you need cups with a size that is different than provided here, rescaling should work fine within a certain range. Just make sure to use the same scaling factors for all cups and try the test models first. Also, upscaling in Z-direction will increase the friction area of the connectors and you might require more force during assembly and disassembly.

Misc

Please let me know what you think. Also, do feel free to drop me a message, if you have problems with printing these or if you have ideas for add-ons or for how to improve the design.

All my models are free and may be used and shared by everyone. I put a lot of time in my designs to get everything right and I hope the result shows. So, if you like my stuff, consider supporting me here: paypal.me/schnelge.

Cheers! ^_^