Let's try this! I have a new card game (Everyone Else Thinks This Game Is Awesome) and with the expansion, the cards don't fit in the box it comes with (surprise!)

I am sure, though, that I could replace the plastic separator inside with something that would allow me to fit all of the cards, as the volume is there, it just needs rearrangement.

I can 3D print, or I can go use the laser cutter at work next week. But I'd rather not reinvent it from scratch.

I have no problem if it's no longer reachable without taking boxes out of the big box — so I can use the horizontal space more.

Annoyingly it doesn't look like they would fit sideways because they're exactly as wide as the box is tall, d'oh!

@vbabka doesn't gain as much space at that point, though I did consider it.

I'm trying with a two-prints option, but it's very tough to fit in.

Okay I managed to design in Fusion a combination that fits everything. And each of the three pieces fit the tray of my printer separately, so I should be able to print it.

Somehow Prusa wants to take 10 hours for each, though, while Cura says it's going to be 3h36m which is more reasonable, IMHO.

Oh plus two hours for the small organizers for the meeps, pardon, grad students. Which is much better than the two plastic bags!

These appear to be nicely aligned grad students, just like @ZachWeinersmith would have liked.

The rest will take a while...

This is how it's *meant* to look like once the 3D printer will be done…

I had to cancel the print on the first layer because it didn't quite adhere properly. So cleaned the bed, and recalibrating, just to be on the safe side.

This is the first of the three trays I need to 3D print. With this, all the cards from the original edition of Everyone Else Thinks This Game Is Awesome fit in the box. There's space for maybe two more small sets for the future.

I realised that I should probably have printed them a little taller to make the box fit more snugly. But maybe I just need to put a cut of foam on the inside of the top to push down on it.

Cura seems to be doing a good job. The next one will take two and a half hours according to it so I plan on printing it in the morning before heading out.

I'm not leaving the 3D printer unattended, even though it's been almost always rock solid after the first few layers, particularly with this material.

So it turns out that the grid infill clashed with the pen tray, so I had to re-print the second piece halfway through because it was being shredded.

The new one with gyroid infill is better, but at 5% infill it does struggle a bit, so I think I'll heed Cura's advice and keep it at 10% for the next.

I also realized I probably could have dropped some weight by splitting this one in three further parts: a hollow, open-bottom raiser (printed upside down), and the papers' tray, and the pen tray.

yeah there's a hole on the finger-slot fror the papers due to the interaction between the flat bottom and the gyroid. If that's the only problem, I'll just stick on some felt to keep it from being "open" but it's literally just aesthetic.

But printing it as a tray to stick on top would have been better for sure. Live and learn.

And this is the second part. The hole is indeed the only aesthetic mark and no functional problems with it. And it fits with the cards' tray.