Designing a custom deck box from card measurements to printable STL takes about 45 minutes in TinkerCAD if you know the steps. This guide walks through the complete process: from measuring your sleeved cards to a functional two-piece deck box ready to export. No design experience required. TinkerCAD runs in a browser with no download.
Step 1: Measure Your Sleeved Cards
Sleeve a stack of 10 cards. Measure with calipers:
- Width of the sleeved card
- Height of the sleeved card
- Total thickness of the 10-card stack
Divide the stack thickness by 10 to get per-card thickness. Multiply by your full deck card count to get total deck depth. Add 2mm for clearance on each dimension that contacts cards.
Example for 60-card Dragon Shield Matte deck:
- Card width measured: 66.5mm → interior width = 68.5mm
- Card height measured: 91.5mm → interior height = 93.5mm
- Per-card thickness: 0.55mm → 60 cards = 33mm → interior depth = 35mm
Step 2: Build the Box Body in TinkerCAD
Create the outer box: In TinkerCAD, add a Box shape. Set dimensions to: (interior width + 4mm wall thickness x2) x (interior height + 4mm) x (interior depth + 3mm base). For the example above: 76.5mm wide x 101.5mm tall x 41mm deep.
Create the inner void: Add a second Box shape set as a Hole. Set to the interior dimensions: 68.5mm x 93.5mm x 35mm. Position it centered on the outer box, with 3mm of wall on all sides and 3mm of base at the bottom. Raise the hole up 3mm from the outer box base to create the floor.
Group: Select both shapes, click Group. The hole subtracts from the outer box, creating the hollow interior.
Step 3: Add a Thumb Notch
Add a Cylinder shape set as a Hole. Set diameter to 18mm, height to 10mm. Position it at the top center of the box interior, cutting down from the top opening. This creates the thumb access notch that lets you push cards up and out of the box.
Group again to apply the cylinder hole.
Step 4: Build the Lid
Create a new Box shape for the lid. Width and depth match the outer box dimensions. Height: 15-20mm. Add an inner void Box (Hole) that matches the outer box top with 0.4mm additional clearance per side (the friction fit clearance). The lid slips over the box exterior.
Optional: add a front lip on the lid — a 2mm tall extended wall on the front face that acts as a finger grip for opening.
Step 5: Add Logo or Text
TinkerCAD’s Text shape adds embossed or engraved text directly to any face. Set height to 2mm for raised embossed text. Set to negative 0.5mm for engraved text. Position on the lid front face or box exterior side.
Step 6: Export
Export as STL from the Export button. Export box and lid as separate STL files (select each independently before exporting). Import into Bambu Studio, print box with open top facing up, lid with open interior facing down. Use eSUN Matte PLA at 0.2mm, 3 walls, 15% gyroid.
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