Universal USPS Media Mail Box

A universal lightweight 3D printable box for storage or shipping small items.

I designed this because I needed to ship many Blu-ray/DVD discs and did not want to use oversized cardboard boxes. The goal was to make a strong, compact and lightweight box that keeps the item protected while keeping the shipping size as small as possible.

This version has a usable inner space of 177 × 140 × 17 mm. These are the internal usable dimensions, not the outside dimensions. If you need the outside size, you need to add the wall and ribs thickness.

The shown example is sized for a standard Blu-ray anime case with about 5 mm of extra space on each side for bubble wrap. This gives a very secure fit for shipping while avoiding unnecessary extra package size and shipping cost. Please check the photos to see the fit.

The design uses optimized 0.8 mm walls with reinforcing ribs. This gave me a very good balance between strength, plastic usage and usable inner space. The lid fits over the box, and there is a seam/chamfer around the lid-box joint that can also help guide tape cutting after the box is sealed.

This model can be used for:
- Blu-ray cases
- DVD cases
- CD cases
- Small flat media items
- Lightweight storage boxes
- Custom small shipping boxes

Print settings used for the uploaded profile:

This model uses a mostly default 0.20 mm Bambu Studio profile and does not require supports.

The design is optimized to print fast. I printed it at the normal high speeds my Bambu printer can handle and had no failures or printing issues. The box has simple geometry, thin 0.8 mm walls, reinforcing ribs and no difficult overhangs, so it prints very reliably.

Recommended profile:
- Layer height: 0.20 mm
- Initial layer height: 0.20 mm
- Wall loops: 2
- Wall thickness in the model: 0.8 mm
- Top shell layers: 2
- Bottom shell layers: 2
- Sparse infill: 10%
- Supports: No
- Brim: Not required for me
- Print speed: default/high Bambu speeds worked well

The uploaded print profile uses fast settings:
- Outer wall: 200 mm/s
- Inner wall: 230 mm/s
- Sparse infill: 230 mm/s
- Internal solid infill: 230 mm/s
- Top surface: 200 mm/s

You can slow it down if your printer, filament or bed adhesion needs it, but for me the default fast profile worked perfectly.

The Fusion 360 file is included. The whole model is parametric, so you can enter your own dimensions and print a custom box for your exact item.

Current model parameters:
- BoxLength: usable inner box length
- BoxWidth: usable inner box width
- BoxHeight: usable inner box height
- WallThickness: box and lid wall thickness
- RibHeight: height of reinforcing ribs
- RibThickness: thickness of reinforcing ribs
- LidOverlap: how far the lid overlaps the box
- EdgeFillet: fillet radius for outer edges
- SeamChamfer: chamfer at the lid-box seam
- LidFitClearance: clearance for lid fit over the box
- LidRimClearance: clearance for box rim inside the lid

Default dimensions in this upload:
- Inner usable size: 177 × 140 × 17 mm
- Wall thickness: 0.8 mm
- Rib height: 0.8 mm
- Rib thickness: 0.8 mm
- Lid overlap: 3 mm
- Edge fillet: 0.5 mm
- Seam chamfer: 0.4 mm
- Lid fit clearance: 0.3 mm
- Lid rim clearance: 0.3 mm

Use it if it helps you. If you modify or improve the model, please share your version with the community too.