I wanted to make a storage case for the "3D Printing Magnet Bundle - 500pc Bulk Pack | 3x2 - 5x2 - 6x2 - 6x3 - 10x2" . Something that kept them from attracting to each other and allowed for easy removal to install in my prints
First Prototype
The original concept was to make a tray for the magnets to sit in. After the initial print it revealed many problems mainly due to the magnets attractive force between each stack
Second Prototype
After the very clear issues with the initial design, i opted to create 'slide out' channels for each size magnet which would hold the magnets in place if the container was flipped and allowed the row to slide forward and easily separate a magnet from the stack. I also added size labels and a 'lid' type design for storage but this prototype exposed some new issues
1) The magnets proximity to each other caused the magnets to pull the neighboring magnets out of the channel.
2) The magnetic strength difference between the 3x2 and 5x2 magnets caused the 3x2 to not want to seat in place in the channel
Third Prototype
With this print (while visually not all that different) i reduced the channel size for the last 8-10mm of the channel to 'grab' the stack hoping this would be enough to stop the neighbouring magnets from sliding out when removing the required magnet. This didn't really work as planned with very little noticeable difference. At the same time i added some 5x2mm holes on the base and lid pocket to make the cover magnetically attach to the base.
Fourth Prototype
Back to the drawing board, after quickly realising i could not compete with the strength of magnets - the only way to improve my design was to create an air gap between each magnet. I opted for a long rectangle design which used the full area of the print bed and allowed the lid and base to print at the same time. I made each channel long enough for 100 magnets (except for 6x3 i used 2 channels) this allowed me to space out the channels to reduce the amount the magnetic fields would affect each other. I have also added thumb groove cutouts in the lid so you can easily lift of the cover (which is magnetically attached with the 5x2) hidden magnets. This design while was improved - it still didn't have the desired effect i wanted. When the tray was flat on the table each row would still drag out the neighbouring magnets.
Fifth Prototype
With the overall design complete, i reduced the final 12-15mm of each channel so it tapered - this meant the magnets 'wedge' in place but can also be removed with minimal effort. This worked really well - with some minor adjustments to the channel tolerance the design will be complete
to be continued....