Organization Insert With 3D Printed Brackets for an IKEA Tjena Box

Using storage boxes like the IKEA Tjena can really declutter a space, hiding objects from sight and more importantly allowing you to group small items into categories so they can easily be found again.

However these boxes can be too deep for smaller items. One knock and the contents are hustled around meaning you'll have to dig around for the item you're looking for.

IKEA used to sell an insert for the medium sized boxes in the range but have since discontinued it. It was nice but had a couple of limitations. For example it had loose hooks which meant a lot of juggling to place or remove the insert. Permanent dividers meant it was almost always unsuitable for what I wanted to use it for.

The insert in this tutorial has integrated hooks, is surprisingly strong, and most importantly can be easily adjusted to fit your needs.

This tutorial is focused on the IKEA Tjena boxes but it can be adapted to fit any box you have.

• Pencil

• Craft knife

• Metal ruler

• Cutting mat

• Glue of your choice (I used wood glue with great results)

• Small clamps

• 3D Printer (or a 3D printing service)

• PLA filament

• 3D slicer (I used Cura)

• 1 mm thick cardboard

The attached file is for a small test piece. The Tjena boxes have a 1 mm wall which is what these pieces were made to fit, for these boxes this step is not mandatory but it can be useful for other types of boxes.

Print two of these brackets to test the fit. Place a bracket on opposite sides of the box and test if the lid still fits over top of them. The brackets should be snug but also be able to slide along the sides of the box.

Print the files below, you will need 2 of each corner type.

I used Cura with the following settings:

• No support

• Layer height: 0,2mm

• Wall thickness: 0,8mm

• Top/bottom thickness: 0,6mm

• Printing temperature: 200ºC (this depends on the material you use, please make sure to check the settings of your material)

• Infill: 20%

I used the smallest Tjena (18 x 25 x 15 cm) to measure the size for my insert. If you're making this for a different box or want to check the sizes for your box, the picture shows you how to measure. Its important to place the corner brackets in the box and measure the space between the interior sides of the brackets.

If you are using the small Tjena, or want to make an insert for half of the length of one of the medium boxes (25 x 35 x 10 or 25 x 35 x 20 cm), then you can use the measurements in the diagram. You'll need one 16,2 x 24 cm piece for the bottom, two 24 x 4 cm pieces for the long sides, and two 16 x 4 cm pieces for the short sides. For the length of the short sides 2 mm was subtracted to account for the thickness of the cardboard on the two long sides (1 mm for each side). If you're using a different thickness of cardboard adjust this size accordingly.

It's always a good idea to quickly test fit the pieces by placing them in the corner brackets to check that they were accurately cut.

We will first glue the bottoms and the sides as these can be simultaneously clamped. If you don't have enough clamps for this start with the bottom piece.

For the bottom piece spread a thin layer of glue (using a scrap piece of cardboard can be very useful) on the bottom of the each corner bracket one by one and clamp. Make sure to use corner 1 and 2 on alternate corners. If you want the insert to fit on both the small and medium Tjena boxes make sure the hooks are all on the short sides.

For the sides spread a thin layer of glue in a 3 x 3 cm square on the two bottom corners as well as the bottom edge (for extra strength). Slide in place and clamp.

Follow your glue's instructions and wait for it to dry.

Next, glue the two short sides. Again spread a thin layer of glue in a 3 x 3 cm square on the two bottom corners as well as the bottom, and side edges. Slide in place and clamp. In this step you can adjust any bending that may have occurred from clamping in the last step by making sure the corners line up wel before clamping.

Try the insert in your box. The pictures show how it fits in both the small and medium boxes. The insert can slide from side to side in the medium box, meaning that you might not even have to take it out when you're looking for an item housed underneath the insert.

If you don't want any dividers then congratulations, you're done!

If you do want dividers first layout your objects to check your needs. There are files for both a 'T' divider and a '+' divider. These can be mixed and matched if desired. Print 2 of the chosen dividers.

Place the divider and your objects in the insert and decide what length each cardboard section of your divider needs to be (the center notch of the divider print should be taken into account with this, only measure to this point.

Cut your cardboard into 3,5 cm high strips and then cut to length.

You can either just tuck these into your printed dividers (one at the top and one at the bottom) for maximum flexibility, or glue them in for a more stable divider.

And you're done! Fill your box and your insert and enjoy having neat boxes where it's easy to find what you're looking for.