Metrology Tool Case
A custom-designed tool case that neatly organizes and protects a digital caliper and steel ruler.
Project Overview
A precision-engineered storage solution designed to organize and protect measurement instrumentation, specifically a Starrett 799 digital caliper and steel ruler. This project demonstrates iterative CAD design methodology and additive manufacturing techniques to create a functional enclosure with appropriate geometric tolerances and ergonomic features.
Development Timeline
Initial Design Phase
Extracted geometric features from Starrett 799 Digital Caliper technical documentation and digitized the profile through CAD reverse engineering. Steel ruler constraints were analyzed to establish custom retention geometry.
- CAD reverse engineering from technical drawings
- Custom retention geometry for both instruments
Version 1: Initial Prototype
First prototype revealed interference fit preventing caliper insertion and insufficient steel ruler groove depth. Identified need for proper manufacturing tolerances.
- Interference fit prevented caliper insertion
- Insufficient groove depth for ruler engagement
Version 2: Refined Design
Addressed failure modes by increasing groove depth and offsetting caliper retention for proper clearance fit. Achieved functional tool retention with ergonomic extraction.
- Increased groove depth for ruler engagement
- Clearance fit for caliper retention
Version 3: Ergonomic Refinement
Added finger relief groove to reduce caliper extraction force and widened steel ruler groove for easier insertion.
- Finger relief groove for easier extraction
- Widened ruler groove clearance
Protective Case Development
Two-piece case with magnetic closure using 2.5-inch neodymium magnets for single-handed operation and complete protection.
- Two-piece construction with magnetic closure
- 2.5-inch neodymium magnets for secure retention
Full-Size Case Assembly
The complete dual-instrument case integrating all design iterations: the refined caliper tray, steel ruler slot, and magnetic enclosure into a unified storage solution.
- Houses both digital caliper and 6-inch steel ruler
- Ergonomic finger reliefs for easy tool extraction
- Magnetic closure enables single-handed operation
Compact Caliper-Only Case
After using the full-size case, I wanted a more simplistic and portable solution. I reduced the case size to hold just the digital caliper, making it significantly easier to carry around for quick measurements on the go.
- Eliminated steel ruler compartment for reduced footprint
- Compact form factor optimized for portability
- Maintained magnetic closure for secure single-handed operation
