Parametric Convertible Deck Box

This convertible card box is made up of two identical card holders that fit into each other. When clipped together, they form a sturdy case that effectively protects your cards, and which you can take everywhere with you or include in your game boxes. Once unclipped, they become two practical card holders which you can use in your games, for example as a draw pile and a discard pile.

The cards rest on an inclined surface in the holder to facilitate drawing and prevent the deck from collapsing. An optional notch is provided for quick removal of the deck or for drawing from the bottom of the pile. In the form of a deck box, the notches reveal its contents.

How to create a customized deck box?

To customize your own, you don't need to know how to use CAD software. Simply install OpenSCAD and open the “Parametric Convertible Deckbox.scad” file. In the customizer panel you have four parameters to customize your deck box:

• card length: Enter the length of the cards you're using (or the length of the sleeves if you're using them) and add 1mm. The length must be between 51mm and 155mm.
• card width: Enter the width of the cards you're using (or the width of the sleeves if you're using them) and add 1mm. The width must be between 42mm and 135mm.
• with notch: check the box to have a notch in the slope (recommended).
• deck height: Enter the height of the deck to be contained in the deck box. Maximum height depends on card length, see below.

By design, the maximum height the deck box can hold depends on the length of the cards in the deck. This ratio is defined by the following formula: maximum deck height = 0.995 x card length - 26 

This table show some typical maximum values for this parameter:

The maximum number of cards may vary according to the quality of the cards (and therefore their thickness) and of the sleeves. Please also note that these are maximum values, and you should use the value corresponding to the  measured deck height of the cards you want to store in the deck box (+ 1 or 2mm). If you use a much higher value than necessary, the cards may move around in the deck box.

Set your parameters as desired and press the Render Button (or press F6) to display the rendered model. If everything is all right, press the Export as STL Button (or press F7) to save the STL file. If an error has occurred (e.g. you've exceeded the maximum deck height), check the red lines in the Console window for the cause of the error and the value you must not exceed.

Sample.stl is the STL corresponding to the default value in the SCAD file. You can found a deck box made with this model for It's a Wonderful World here.

Print Settings

Layer height: 0.2mm

Number of perimeters: 4 for a 0.4mm nozzle, 3 for a 0.6mm nozzle

No supports are required. Print the deck holder twice in this orientation:
 

PLA and PETG are good material choices. I don't recommend Silk PLA because the quality of their overhangs is poor.