After a few attempts to print and assemble the awesome CCG Deck box with gears I decided to redesign it. The concept was brilliant but in my opinion the puzzle piece construction was ideal for laser cut wood or plastic, not 3D printing.
The old design was difficult to assemble (in my experience lots of glue, broken ends, and exacto knife cuts) and required many prints to complete (see photos for comparison). This "functional reprint" (eh? eh? Ok ill go home) is designed to print faster, assemble easier, and work better. Let me know what you think in the comments section.
The front, back, side, and inner pieces were all combined into one, easy-to-print solid.
The pinion gear is now held in place by a pin. This relieves stress on the top hinge and makes for a more robust open/close operation.
The bottom has a simpler shape and easily snaps into place.
The entire assembly has been carefully calibrated to fit.
Holds 100 sleeved cards nicely. Also holds 60 cards plus a 15 card sideboard well.
2/10/15 -- I added deck boxes with mana symbols and added a lower profile pin.
6/5/2015 -- Made a small change to the main body model to allow easier assembly. It was difficult to slide pins into place.
None of these parts require support. Dont do it.
Most of these print flat so make sure your bed is level. Warped parts may not fit right
I recommend printing on low 0.3mm.
The main box body should be printed with a raft. Do not print with support. This was printed on a rep 2 and the small gaps were easily bridged.
Each piece is uploaded separately so you can load your bed however you like. If a piece needs to be printed in duplicate, the file name should say so.
Assemble the two rack and bottom lift plate parts and insert into the main box. Then, put bottom cover on.
For hinge pins I used wire brads/hanging nails (the exact size is on the box pictured in the gallery). Snip the heads off with wire cutters and insert one on each side. Then, use a blunt nail to drive them in all the way.