Details

Modified the Parametric Rugged Box by TheSameNameTwice to hold 48 AA batteries. They have an AA holder as well but it holds fewer batteries and isn't staggered. I chose 48 because that's the size of AmazonBasics AA batteries I usually purchase.

Note that I also modified the original Parametric Rugged Box's hinge mechanism to make it easier to install whilst maintaining the rigidity. Also trimmed down the locking mechanism so it doesn't feel like it'll break every time I close the box.

I added a file aa_sample.stl that has a few AA holes that I recommend testing with to make sure your AA's will fit into the holes in the box. I've found that some AA batteries are a little thicker than others for whatever reason.

Related

See my AAA battery holder as well!

Printing

Nothing should need supports. Make sure you're printing the bottom part, bottom side against the build plate, and the top part, top side against the build plate.

I printed with a 0.2mm layer height with 15% gyroid infill, came out more than strong enough. I used Prusament Galaxy Silver PLA on my Prusa i3 MK3S+ printer.

What I used:

Software: PrusaSlicer 2.3.0
Printer Used: Prusa i3 MK3S+
Supports: No
Adhesion: Skirt
Layer Height: 0.2mm
Infill: 15% Gyroid
Filament Used: PLA Galaxy Silver by Prusament

How I Designed This

I wanted mine to be more dense than the current remix for the original Parametric Rugged Box so I went down a rabbit hole looking for the densest organization of circles within a rectangle. Ended up finding Packomania which gave me the exact coordinates to place each circle at. Navigate to Circles in rectangles with variable aspect ratio and choose 48 to see the layout. Pretty interesting stuff.