A 3D printed MTG deck box has one job: hold your cards without stress, friction, or accidental damage while keeping them accessible. Getting this right requires understanding the actual dimensions of sleeved cards, how PLA shrinks from nominal dimensions during printing, what tolerances allow smooth access without rattle, and how to design a lid that closes securely without requiring two hands to open. This is the complete reference guide for anyone designing or evaluating MTG deck boxes.
The Card Dimensions You Actually Need
A standard Magic card is 63mm wide x 88mm tall x 0.305mm thick (nominal). Sleeved cards change all three dimensions:
| Configuration | Width | Height | Thickness per card | 100-card deck depth |
|---|---|---|---|---|
| Unsleeved | 63mm | 88mm | 0.31mm | 31mm |
| Single sleeve (KMC Perfect Fit) | 64mm | 89mm | 0.38mm | 38mm |
| Single outer sleeve (Dragon Shield Matte) | 67mm | 92mm | 0.55mm | 55mm |
| Double sleeved (Perfect Fit + Dragon Shield) | 68mm | 93mm | 0.68mm | 68mm |
These measurements are from real-world sleeving, not manufacturer specs. Manufacturer specs are the sleeve outer dimension, not the sleeved card dimension. The card compresses the sleeve slightly.
FDM Tolerance for Deck Boxes
PLA prints approximately 0.2-0.3mm undersized in XY dimensions on most calibrated FDM printers due to material shrinkage and line width compensation. For a deck box interior, this means the modeled dimension needs to be the actual sleeved card dimension plus a clearance budget.
Recommended clearances for smooth operation:
- Width: card width + 1.5-2mm total (0.75-1mm per side)
- Height: card height + 2-3mm (room for thumb access at top)
- Depth: deck depth + 2-3mm (lid closure clearance)
For Dragon Shield Matte single-sleeved 60-card Commander deck: interior 69mm wide, 94mm tall, 35mm deep gives a comfortable fit with smooth card access. This is the baseline for OreKo Commander deck box designs.
For double-sleeved: interior 70mm wide, 95mm tall, 70mm deep for a 100-card Commander deck.
Lid Design: What Actually Works
Friction fit lid (most common): The lid has a lip that slides over the box exterior with 0.3-0.4mm clearance. Too tight: lid requires two hands and excessive force. Too loose: lid rattles and falls off. Print a calibration test box 40x40mm with matching lid, adjust clearance until the lid seats with light finger pressure and releases with a gentle tug.
Magnetic lid: N52 magnets embedded in the lid and box body create a satisfying snap-close. Magnet pair positions: two pairs in a symmetrical arrangement ensure the lid seats without rocking. See the September magnet guide for the embedding technique.
Hinge lid: A printed TPU living hinge connects lid to box in a single piece. The hinge allows 180-degree lid opening and keeps the lid attached. Best for boxes that will be opened frequently and in conditions where a separated lid might be lost.
eSUN Matte PLA is the OreKo default for deck boxes. The matte finish doesn’t show fingerprints, accepts paint and surface treatment cleanly, and produces a premium non-plastic tactile quality that glossy PLA doesn’t.
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