Iris Door Box v3

created by Sean Charlesworth

sean@charlesworth-dynamics.com
Print one of each part, my settings using ABS on a MakerBot 2X have been:
Gear ring and slot ring - .2 layer/ 0%-5% fill/ 2 shells
Leaves - .2 layer/ 5-7% fill/ 1 shell
Base - .2 layer/ 0% fill/ 2 shells - the 0 fill is important here since the wall
s are so thin. I find that using anything other than 0 shakes the machine like c
razy and tends to jam the nozzle.
You will need 5 pan-head screws for each box: #4 x 1/4" (M3 x 5 or 6mm should wo
rk as well)
1) Depending on your printer and quality of prints you may have to clean up som
e of the parts to remove burrs and get holes to the correct size. Along those
lines I would recommend running a screw through each leaf pivot hole to ensure i
t's the correct size. You may want to do this with the gear ring as well, but D
O NOT screw them in too far or you will drive them through the top of the gear r
ing.
2) Next we need to set up the iris leaves. Place the slot ring face up and put
a quarter in the middle. The quarter will hold up the tips of the leaves as we
place them. The channel on the bottom of each leaf goes on the pins of the sl
ot ring. Place all the leaves and tweak them so the are aligned with the edges
of the slot ring and all the leaves fit together. The leaves may need trimmed t
o improve the fit. Once the leaves are positioned, carefully put a piece of tape
across the center to hold them together.
*** OPTIONAL - print out the leaf_jig.stl to help assemble the leaves and slot r
ing. It aids in alignment and holds up the leaf tips. You should only need thi
s if you plan on making a bunch of boxes. ***
3) The gear ring
each hole so the
d. Set it on top
so the gear ring

is next. You may want to place a small amount of superglue in

screws have no chance of working their way loose once assemble
of the leaves/slot ring assembly and flip the whole thing over
is on the bottom.

4) Due to variances in prints, assembly of the leaves, etc I have found that th
ere is usually a sweet spot when lining up the leaves with the gear ring. Rotat
e the leaves/slot ring assembly until all the holes line up as close as possible
with the gear ring holes. Now carefully start putting the screws in but do not
over-tighten!
5) Ideally the screws should have a slight gap betweem their heads and the slot
ring. Squeeze together the gear ring/leaves/slot ring sandwich and tighten scr
ews accordingly. Make sure to take the tape off that was holding the leaves. T
est the mechanism by inserting the 'keys' on the base into the pathways on the u
nderside of the slot ring. Firmly pressing the base against the mechanism, test
by turning the gear ring. IT SHOULD NOT be hard to turn. If it is, stop and b
ack off the screws a little. The goal is to have some friction so the box stays
close but is still easy to open and close.
*** ALWAYS USE THE GEAR RING TO OPEN AND CLOSE THE BOX. PUSHING ON THE LEAVES T
O CLOSE IT WILL USUALLY SNAP OFF THE GUIDE PINS ***

6) Once the mechanism is adjusted to your liking, glue it to the base. I gener
ally use a 4-6 dabs of superglue around the edge of the base which holds it toge
ther well but also allows for prying it apart if needed.
Now make a whole bunch because everyone will ask for one.