My wife wanted a letter organizer/holder for her desk. I really liked the original design, located here, but I wanted to make it larger in size. Along with the larger size, I made additional sized separators (2 - 7 hexagons high), as well as added a fourth separator groove.

The bottom plate labeled “looser fit” has grooves that are .1mm wider for the separators to fit into. The plate labeled “tigher fit” has grooves that are exactly the same size as the width of the separators, 2.3mm. When I printed the tighter fit with bambu lab PLA CF, the tolerances were tight enough that it didn't need glue.

The heights of the separators is as follows:

• 2 hexagons - 193X90
• 3 hexagons - 193X100
• 4 hexagons - 193X120
• 5 hexagons - 193X140
• 6 hexagons - 193X158
• 7 hexagons - 193X178

There are still artifacts that you can see on the model of where I cut and joined pieces in tinkercad. Any recommendations on how to get rid of those is welcome. In my test prints, those artifacts do not show up in the print.

I printed the separators face down on the build plate. I tried printing them standing on edge and that didn't work out very good.

I only applied brim to the base piece, and that was just to keep from warping as I have had issues before.

For added strength and weight, I printed everything in 35% gyroid infil

Thanks to Hatchet for the original model.