Hexagon A4 Paper Tray - Modular Design

Another project that is a bit over the top to solve a very not over the top problem.

Cool thing is though you can build it as high as you want and it is definitely very strong!

When I was designing this, I thought it made sense to cut the tray into four pieces (left front, left rear, right front, right rear) so that the design would fit on the print bed. And also I wanted to create a tray that wouldn't use too much filament but also had some strength behind it!

You'll notice in the images that the four pieces that make up one tray level are joined together with two M3 screws on each join (in the picture these joins are the stainless steel screws you can see, I'm not referring to the black screw joins).

Then you'll notice that EACH tray level is then attached to subsequent levels through the use of a diagonal bracket (3 for the left side and 3 for the right side) and this helps to create distance between levels, to reduce material required, and to add consistency to the final result, hence a modular design :-)

I also had a huge stockpile of spare M3 screws so I kinda wanted to have that metal and plastic look. 

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Note on Print Times

Front page description shows print time of all STLs in total. I think I should outline how many of each part you would need to print, then you can do a rough calculation of how long you'd need to print.

Print times here are based on a MK3S with a 0.6mm nozzle! Quite a bit faster than 0.4mm, but I'll upload the 0.4mm GCODE soon so then the print times will be available for 0.4mm.

Trays:
Left Front Tray - 52minutes (26g) (1 required for EACH level)
Left Rear Tray - 52minutes (26g) (1 required for EACH level)
Right Front Tray - 52minutes (26g) (1 required for EACH level)
Right Rear Tray - 52minutes (26g) (1 required for EACH level)

Brackets:
Left Side 5space Bracket - 13minutes (5g) (3 required for EACH level)
Right Side 5space Bracket - 13minutes (5g) (3 required for EACH level)
Left Side 3space Bracket - 13minutes (5g) (Not required if using 5space bracket)
Right Side 3space Bracket - 13minutes (5g) (Not required if using 5space bracket)
Left Rear Bracket - 17minutes (7g) (1 required for EACH level)
Right Rear Bracket - 17minutes (7g) (1 required for EACH level)

Legs:
Left Side Leg - 12minutes (4g) (3 required in total)
Right Side Leg - 12minutes (4g) (3 required in total)

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Screws Required

M3 12mm (minimum) for brackets and legs
M3 8mm (minimum) for joining left and right, front and rear trays
Note:

• Each level of trays require 8 screws and 8 nuts
• Photographed assembly shows 6 SIDE BRACKETS for each level (3 on the left and 3 on the right) requiring at least 24 screws and 24 nuts for each level
• Rear section uses 2 REAR BRACKETS per level requiring 8 screws and 8 nuts
• Photographed assembly shows 6 LEGS for the base level (3 on the left and 3 on the right) requiring at least 12 screws and 12 nuts for the base
• If my maths is ok... that's at least 264 screws and 264 nuts to build the pictured 7 layer stack, but I might be wrong!

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Download includes sliced GCODE for MK3S with a 0.6mm nozzle (0.4mm nozzle GCODE coming soon!)

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No Supports Required!

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MadebyA2 Paper Tray GCODE Creation

19 February 2021
PrusaSlicer Version 2.3.0 (+win64)

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Version History

V1 - 19 February 2021
Deleted and re-uploaded all STL files to ensure orientation of STLs was correct
Re-uploaded GCODE for MK3S 0.6mm nozzle

V1 - 18 February 2021
Initial upload for the Prusa Let's Get Organized Contest
Original STLs, photographs, design captures and GCODE (for 0.6mm nozzle)

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Print Instructions

Print Settings
MK3S 0.6mm Nozzle
PrusaSlicer Preset = 0.35mm SPEED (modified)
Vertical Shells = 3
Infill = 20% Gyroid
Brim = Off (or On if you like using brims!)
Support Material = None!

Filament Settings
PrusaSlicer Preset = Prusa PLA