Submitted by: GemPrinted

Overview The FlexBox Generator is a code-driven design engine built entirely in KCL. It eliminates the need for manual CAD sketching, complex assemblies, or external hardware. By mathematically defining living hinge flexures, this script generates a custom, flat-pack enclosure that prints in one piece and snaps together into a rigid 3D box. What It Is At its core, this is a compliant mechanism compiler. Designing living hinges manually is tedious and fragile—if you stretch a standard CAD model, the hinge gaps distort and the print fails. This KCL engine solves that by programmatically calculating the bend allowance and generating the required staggered slots across the flexure zone. It ensures the material (ideal for FDM plastics like PETG) can cleanly fold 90 degrees without snapping, snapping securely into place using an integrated locking tab. Use Cases Because the engine is fully parametric, it can be instantly adapted for endless applications: Product Packaging (Logo Boxes): Generate custom-sized, snap-fit boxes featuring a debossed logo on the lid for professional, zero-waste commercial packaging. Custom Gift Boxes: Quickly compile unique, geometric gift enclosures that showcase advanced 3D printing techniques. Hardware & PCB Enclosures: Create precise, zero-hardware project boxes to house electronics, custom controllers, or mechanical assemblies. Modular Storage: Build custom-dimensioned organizers that print flat to maximize build-plate efficiency. How to Use the Parameters The geometry is completely driven by a few simple variables at the top of the script. By adjusting the boxLength and boxWidth parameters, the code dynamically recalculates the entire flat-pattern footprint. As these dimensions change, the engine automatically scales the panels, repositions the snap-fit latch, and recalculates the number of required slots in the living hinge loops to maintain perfect structural integrity. Note: The engine includes built-in manufacturing constraints to ensure your generated boxLength and boxWidth flat-pattern does not exceed the limits of a standard 256mm build plate.