Rails for Bosch / Sortimo i-Boxx Organizer Box

These are rails for the i-Boxx organizer boxes that can be used to build custom storage cabinets. The boxes are available from Bosch, Sortimo, BS Systems, and potentially other manufacturers.

The rails work with the i-Boxx 72, i-Boxx 53, and LS-Tray 72 a.k.a LS-Drawer 72.

The documentation below contains all the information you need to build a complete storage cabinet for your boxes. STEP files are available for easy remixing and for use in your CAD assemblies.

Required Hardware

Each rail requires 6 to 3 (12-6 per pair) screws. The full length version requires at least 3 screws and the split version requires at least 4 screws. You can add the remaining screws for additional strength but they're optional.

The screws should be 2.5mm or 3mm in diameter with a head diameter up to 5.8mm. Button head are preferred but countersink screws work as well. I used Spax Universal Z1 2.5x10mm screws for 8mm thick MDF panels.

The length is determined by the thickness of the material you want to use for your storage cabinet. Read more about it in the “Assembly” section below.

Full Length Version or Split Version

It's all about the build volume. The rails are available in two different versions to support smaller printers. The full length version measures 268mm and requires roughly a 300mm bed. If you have a smaller printer you can use the split version instead, which measures 133mm and can be printed on most small printers. The split version has no functional disadvantages. You can also mix and match as you like.

Printing

Print the parts in the original orientation. All STL files are pre-rotated.

If you print the full length version you might want to use some adhesion helpers, such as adhesion sprays or a brim, as the part is very long and skinny and has a higher tendency to warp - especially if your printer's bed isn't heated very evenly.

• Material: Doesn't matter, anything solid
• Perimeters: 3 or more
• Infill: 15%
• Supports: no

Assembly

This covers the basic dimensions for a storage cabinet. Using these dimensions, the box will slide in easily and it'll make the most efficient use of the vertical space and leave only a small vertical gap between the organizer boxes. Thee will be about a 5mm gap between the organizes boxes and the front face of the storage cabinet.

Inner Dimensions

The left and right inner walls of your storage cabinet should 371mm apart for easy insertion of the organizer boxes. A little smaller, 370mm or 369mm, would work as well but there'd be less wiggle room. The inner height is determined by the type of organizer box and the number of boxes you want to store.

• Inner width: 371mm
• Inner depth: 326mm
• Inner height: see formula below

Calculating Inner Height

Replace NUMBER_OF_BOXES with the number of organizer boxes in your cabinet in the formulae below.

• i-Boxx 72: 7mm + (NUMBER_OF_BOXES * 77mm)
• i-Boxx 53: 7mm + (NUMBER_OF_BOXES * 58mm)

Screw Hole Pattern

The following drawings show the hole pattern of the inner side of the left wall of the cabinet. For the right wall the screw hole pattern is mirrored.

Screw Length

The maximum screw length is determined by the thickness of your side walls. The screw hole on the rail is 3mm deep. The maximum screw length is the wall thickness + 3mm rounded down to the nearest standard screw size.

With an 8mm thick panel the ideal screw length is around 10mm.

Assembly Jigs

If you prefer to use jigs and install the rails as you go instead of marking all the screw holes in advance, please refer to the image below to see how to use the assembly jigs. The jigs with a number are only for i-Boxx 72 or i-Boxx 53 respectively. The jigs that end in “S” are only needed for the split version of the rails.

• F: Distance to front of the cabinet
• B: Distance to the bottom edge
• V: Vertical spacing between rails
• S: Ensure 2mm gap between front and rear of split rails
• 72: For i-Boxx 72
• 53: For i-Boxx 53

Note: Instead of jigs BxxS and VxxS you can also just use jig S that just maintains the gap between the front and rear split rails without the vertical spacing. It can be printed flat and prints quicker.