Update: Aug 23, 2022

Updated the card tray to handle the extra Frontier cards from Codex 3, as well as the action cards from Codex 2 (I think... I had some sitting in a bag that were sleeved, so they weren't replaced.) Base of the tray is 5mm wider, but still fits in the box.

I haven't decided if I'll do anything with regards to the new faction (Keleres) since most of the components are reused from another race.

Update: Jan 28, 2021

Added photos now that printing (over 2 weeks straight during waking hours!) is done. Everything fits, albeit with a small rise in the lid for manuals/playboards.

My copy of Prophecy of Kings finally came in, so I'm currently redoing the containers as they are slightly small to accommodate the expansion content. (Race boxes, player boxes need more space for cards, Tile holder and card holder needs to be completely redone for new content.)

New Models will have _v2 appended to the filenames and I will add them as I confirm the designs work with my own set.

Done:

• Race_Box_Base_v2 - 5 mm thicker overall, but still compatible with old lids if you've already printed them. (Though they do not cover the full box.)
• Race_Box_Top_v2 - New lid which covers full depth of new box.
• Race_Box_V2.f3d - Parameterized Fusion 360 file. You can easily adjust the depth for token space and card space to suit your own collection / sleeves.
• Player_Box_Base_v2 - Card space is thicker to accommodate additional cards. Fillets reduced to reduce wasted space in original model. Slightly shorter in height. NOT Compatible with old lids, sorry.
• Player_Box_Top_v2 - Shorter edges. Didn't really see a need for the extra material.
• Player_Box_V2.f3d - Parameterized Fusion 360 file. There are a number of parameters that can be adjusted to change the model to suit your needs.
• TileHolder-HomeAnomaly_v2 - Split tile holder into two (Systems (Blue) / Hyperlanes and Home Systems/Anomalies)
• TileHolder-SystemsHyperlanes_v2 - Other tile holder. Note that while the parameters seem to be accurate for large number of tiles, the hyperlanes section was tight in my original print. I've since added another "tile" to give it some wiggle room in the STL.
• CardTray_v2 - Card holder. Measurements are tight as I had to fit this in the remaining space in my box. Still, managed to get all cards in their own sections, fully sleeved. Note that this print will take ~16 hours to do. I may do a half-height one in the future, or you can download the fusion model and change the BoxHeight parameter.

Containers for Twilight Imperium 4th Edition.

While 4th Edition provides a nice, full box insert for the game, the insert is not well designed to handle cards with sleeves, nor does it make it easy to get at the players pieces.

So, 3D Printing to the rescue.

All containers have been designed with a .25mm gap around the lid. It's tight, but it's what worked to get a snug, but not permanent fit on my printer. You may need to scale up the lid slightly depending on your settings. (I printed at 0.2mm)

Test the fit before you put pieces in! I got carried away and fully closed a box that was full. had to destroy the box to get the pieces out again. If it's too tight, look for areas that might be sticking out (On the race boxes specifically, I always had one corner on the tray that had a slight bulge that I could trim with a knife)

Ship Boxes:
While I originally tried to make them fit within the confines of the insert, it just wasn't possible to fit all of the pieces and the cards as I wanted to do it. So I ended up with a slightly larger box, but still sized such that 3 of them sit along the short edge of the box.

The card section in the ship box holds all coloured technology cards, ship upgrades and the 4 common promissory notes for that colour. It's a tight fit with sleeves, but perfectly doable. There is a notch on the bottom of the tray so that the cards can slide out with ease in a pack.

Ship Bottoms took 10.5 hours to print at 60 mm/s. The lids took about 3.5 hours.

Race Boxes

While the design for 3rd edition was nice and had the command counters in a dedicated section, I decided to forego that design in favour of something more compact. Holds all tokens (including race specific tokens!) and all race-specific cards (Technologies, Home Planets, Race-specific promissory note)

As mentioned above, check the fit on this one before committing your pieces to the box! I had a slightly tighter fit on this one than expected that was caused by a small printing artifact (same start point on each layer caused a very slight bulge on one corner that was easily trimmed using a knife)

Lid and base printed at the same time took 3.5 hours to print one set at 60mm/s, 0.2mm layer height.

Card Tray
Holds all other sleeved cards for the game. Sections for Stage 1 Objectives, Stage 2 Objectives, Secret Objectives, Planets, Action Cards, Politics cards.

The model as provided does not have the symbols. I found they didn't print well, so opted to remove them.

Space Tiles
I've posted two versions of a hex holder for the space tiles. It's probably unnecessary to have the extra side along the top, but I thought it looked neat. Still, I provided both versions so you can choose which one you want to use.

Anything Else?
I've opted to use small containers for the dice, ground force / fighter / trade good tokens rather than design a specific box for them.