Carbon Inspired Strong Wall Mountable Modular Hex Box

Update :
2021.02.19 - Added a V2 cage wall that uses even less material with a honeycomb pattern.

This is a fairly large and strong Modular Storage that can be expanded as much as you wish. It is primarily designed to be mounted onto a wall through screws into wall studs, but it is usable even on a table as a general purpose container.

Every piece in the project is designed with 2 key purposes in mind. (a) Print without support. (b) take advantage of a mirror smooth finish when printing on glass/mirror without any glue to get a --- mirror smooth finish on one side --- this looks awesome btw.

Each module is larger than the size of the largest toilet paper roll you can buy. It is about 120mm deep and 150mm from opposite corners.

Print settings : FWIW, 0.3mm looks ok, but if you really want the posts to look nicer, 0.2mm will make it a lot smoother, however, 0.3mm is reasonable to me.

1. This needs lots of M4 nuts and M4 x 20mm (or 25mm) bolts, as each post requires 2. (one compartment will need 12 bolts and 12 nuts.) The attached pictures are hopefully self explanatory. To use each post, you need to prepare 2 M4 hex nut and two printed M4 6mm hex trims. Insert the M4 nut and trims as shown in the diagram using an M4 bolt - this is the easiest way I found to get the trims to cover up the M4 nuts completely.

2. Once a nut and trim is within one side of the post, unscrew the bolt and tap the trim flush. Now you need to insert the 9mm Top bar at top and bottom. Note that if a post connects to two walls, you need the 9mm Top bar to go in on two sides of the post at the groove sides. Flip one of the top bars over and insert a single hex washer (grooved) in the middle.

3. Insert the walls into the grooves of the tower and the top and bottom bars. When you close the other side with a post, you have completed a single wall. Now the rest of the hex compartment will be an interesting (yet simple) puzzle to solve.

4. To extend beyond just a single compartment, I designed a 6mm high version of the 9mm bar - along with a 3mm trim to glue to the top --- yes, I go into great lengths to avoid using supports when printing. Any post that has 3 bar connectors radiating out, one of the bars has to use the 6mm bar and the top trim. And the walls attach the same way.

5. I have supplied a cage wall with tiny hex openings (to save some material and for aesthetics), along with a solid wall. Choose whichever wall you prefer. Of course, you can design your own wall with interesting patterns as long as it is 2mm thick (or less) and 68.8mm by 114mm, it will fit.

6. The back (or bottom) wall can be attached to posts through two opposite points, Note that there are three holes to use regular flat head tapered screws that can be securely attached to a wall stud or any wood. There are also 16mm hex trims that can be used to cover up the opening after you have attached the back. You need 3x 16mm hex trims for each compartment.

Be aware that objects this big uses a lot of filament, I used 25% infill and still chewed up more than 1kg of a 5kg black spool when I printed all the prototypes and the final version with 4 compartments. I found that using color in the back plate looks better than using the same color for everything. I would expect contrasting posts and walls could also make the thing stand out further as a wall art.