ScrapMate — a Flat File Scrap Organizer

When I saw the theme for this project, one of the first things I thought about was all the scrap paper that doesn’t get properly kept. As an industrial design student, I constantly deal with scraps that don't fit into standard paper trays and often end up being thrown away. This seemed like a waste, so I designed ScrapMate to suit my own needs — and hopefully it will help others who face the same problem.

For this project, I focused on creating a digital prototype and adaptable design, so others can build it in a way that fits their own materials and tools. I’ve also included an F3D file of my model below, along with Build Notes near the end of the post, to make it easy for others to adapt and build their own version of ScrapMate.

Fusion 360 (for modeling, rendering, and animation)

I started with the challenge of combining three ideas: indoor use, sustainability, and reusability. I also gave myself the constraint that the design had to be simple enough for others to build, since it would be going on Instructables.

I explored ways to encourage reuse of paper scraps and to store them more effectively. After brainstorming, I sketched out some inital concepts for a flat file bin, sized to accommodate tabloid paper, letter paper, and scraps.

As I worked through the design, I found a few ways to simplify the build and make it easier to use:

1. Simplified the structure: separated the bin into two "floors" instead of three to reduce bulk and make it more practical to build.
2. Improved access: removed the ceiling for the letter paper compartment and widened the openings overall to make accessing stored paper easier.
3. Enhanced lid usability: replaced the original handle with a visible lid gap and added filleted edges to the scrap compartment lid for better usability and visual clarity. I also want the lid to be somewhat transparent, so the user is visually reminded that scraps are being kept inside.
4. Refined hinge design: extended the hinge to span the entire width of the scrap compartment for a cleaner look and smoother operation.

With the refined design ready, I moved on to modeling the final version in Fusion 360 using simple tools: Extrude, Sketch, Fillet, Rectangular Pattern, Offset Plane, and Combine. Steps 4 through 7 will cover how I built each parts using these tools.

The main body was created as a 12" x 18" x 4" box, with openings cut (using the Extrude tool) for each paper compartment:

1. The bottom compartment (11.5" x 17.5" x 2") is big enough to hold tabloid paper and was cut into the front face.
2. The top right compartment (8.75" x 11.5" x 2") is big enough to store letter paper, with openings on both the front and top faces for easier access.
3. The top left compartment (8" x 10" x 1.55") is for any scraps smaller than letter paper, cut from the top face of the model.

To hold the lid securely, I created a small 8" x 0.5" x 1.55" step ("stopper") using the Offset Plane tool, which prevents the lid from drooping when closed (Image 1). The lid itself was modeled to fit snugly into this step/groove. The hole for the lid was cut as a 10.5" x 8" rectangle to provide clearance for the step and to include a 0.2" gap on one side to allow fingers to easily lift the lid (Image 2 and 3).

At this stage of modeling, the lid was still sized to match the full 10.3" x 8" opening (Image 4). In the next step, I adjusted the lid dimensions to 10" x 8" and finalized the gaps to allow smooth operation.

On the hinge side, I reduced the lid dimensions to 10" x 8", subtracting 0.3" from the lid width to create a 0.3" gap between the lid and the side wall for proper tolerance and smooth hinge operation (Image 1).

I then modeled a simple hinge pair (one piece attached to the lid, one to the wall), and used the Rectangular Pattern tool to replicate them across the hinge side (Images 2, 3, and 4). I included a 0.02" gap between the alternating hinges to ensure the pattern aligned correctly.

After making all the hinges, I used the Combine tool to attach the hinges to the appropriate bodies (Image 5).

Each hinge block was modeled at approximately 0.24" x 0.24" x 0.4", with a hinge pin diameter of 0.1" and an outer hinge diameter of approximately 0.18" (Image 6). These dimensions can be adjusted depending on the material used when crafting.

Finally, I added filleted edges to the lid, key contact surfaces, and exterior edges to improve both usability and visual clarity.

To visualize the final prototype, I used the Appearance tool to try different skins and the Render workspace in Fusion 360 for my final thumbnail photo shoot (Images 1 through 6).

I also created a simple animation of the lid opening using the As-Built Joint's Revolute tool, to help demonstrate the intended interaction.

This project is designed to be adaptable to different build methods and accessible to a wide range of makers:

1. The main structure can be built from recycled plywood, scrap MDF, or other sustainable reclaimed sheet materials.
2. The lid is designed to be hinged for easier access to the scrap compartment. In my steps, I made the hinges to be built-in, but they can be made separately and then attached to the body and lid. I recommend using recyclable materials, such as stainless steel or using eco-friendly filament if 3D printing the hinges. Alternatively, the lid can be adapted as a fully lift-off lid or even built without a lid if a hinge is not desired.
3. The compartments are simple rectangular prisms and do not require complex joinery, making this an approachable woodworking project.
4. For those interested in 3D printing, the model can be adapted for printability. Given the size of the organizer, I recommend slicing the design into smaller sections that can fit standard 3D printers. The parts can then be assembled using simple joints, alignment pins, or strong adhesives such as superglue.
5. The design can also be scaled down to fit only letter paper and scraps, making it more compact and easier to build on smaller equipment.

I included an F3D file of my model here, in case anyone would like to view it or adapt it for their own use!

This project began as a way to solve a simple problem in my own workspace, but I hope it can encourage others to think about how we can design for reuse and sustainability in small ways. Even if they aren't a design student like me who needs frequent access to tabloid paper or scrap, all of the compartments can be used for other types of paper or supplies.

In the future, I would love to explore adding modular dividers to the scrap compartment, to better organize different types of material scraps such as acrylic off-cuts, cardboard, veneer, or chipboard of varying sizes. This would make ScrapMate even more versatile for makers who work with mixed materials. I would also love to physically build this design one day, as I would definitely find it useful for my school work.

Again, for this project, I focused on developing a digital prototype and versatile design, so that others can easily adapt and build ScrapMate, rather than fabricating a single version myself. The provided Fusion 360 model and Build Notes are meant to support that goal.

While the concept may seem simple, I focused on creating a design that would actively encourage better reuse habits, with subtle design choices to make saving scraps easier and more satisfying. I believe that thoughtful, well-considered design can make a meaningful contribution toward sustainability.