Revolutionary Milwaukee Packout Hack

Revolutionary Milwaukee Packout Hack

Table of Contents:

  1. Introduction
  2. Discover: Coming up with Ideas
    • Inspiration for Product Ideas
    • Setting Unique Criteria
    • The Idea: Rotating Hook for Pack Out System
  3. Design: From Idea to CAD
    • Sketching vs CAD
    • CAD Modeling for 3D Printing
    • Optimizing Designs for 3D Printing
  4. Prototype: Printing and Testing
    • Selecting the Right Printer
    • Prototyping Process
    • Strength Testing
  5. Expand: Exploring New Ideas
    • Refining the Design
    • Experimenting with Fully 3D Printed Hooks
    • Creating Accessories for Pack Out System
  6. Deliver: Marketing and Selling
    • Listing Products on Website
    • Social Media Marketing
    • Reaching Target Audience
  7. Conclusion

Behind the Scenes of Designing and Prototyping Products for the Pack Out System


Have you ever had a new product idea? Are you a fan of Pack Out and tool accessories? Or do you want to learn more about 3D printing? Today, I'm going to take you behind the scenes of my design and production process. I will show you how I go from idea creation to prototyping, publishing the listing, and selling it on my website. The steps in this article will boil down to something I like to call "thinking in 3D" - not just three dimensions, not just 3D printing, but these 3DS: discover, design, and deliver.

Discover: Coming up with Ideas

The first phase of any good product is coming up with the idea. Drawing inspiration from various sources, I set unique criteria for each product. For this article, I will be working through a brand new idea: a rotating hook for the Pack Out system. This idea was born out of the need for an easily removable hook that can rotate enough to give access from the front or side of the box. Additionally, the hook needs to be strong enough to hold a 10-pound dumbbell. With these criteria in mind, I dive into the design phase.

Design: From Idea to CAD

Some people recommend sketching out the idea first, but I prefer to jump straight into Computer-Aided Design (CAD) if I have a clear enough image in my mind. Using a blank template file, I start adding geometry for the rotating mechanism. The modeling section of this article will be brief, but if you're interested, let me know in the comments and I can provide more detailed modeling tutorials optimized for 3D printing.

Prototype: Printing and Testing

After finalizing the design in CAD, it's time to bring it to life through 3D printing. Using my selection of printers, including the fast and reliable Bamboo Lab printers, I print out the models. Prototyping is a crucial aspect of the design phase as it allows me to identify any areas that need tweaking for future versions. By attaching the printed parts to the Pack Out system, I can test the strength and functionality of the rotating hook. The results of the strength tests are exciting, with the printed parts successfully holding weights of up to 26 pounds.

Expand: Exploring New Ideas

With confidence in the strength and functionality of the rotating hook, I am inspired to explore new ideas. I experiment with fully 3D printed XL hooks, a level holder, a pipe bender holder, and an XL cup. These additions to the Pack Out system expand its capabilities and offer more options for users. If you have any ideas you think I should create, feel free to drop them in the comments. I am always looking for new product ideas to bring to life.

Deliver: Marketing and Selling

Once prototyping is complete and the designs are finalized, it's time to focus on how I'm going to sell these products. I list them on my Squarespace website and market them on social media platforms such as Instagram and TikTok. The process involves adding images, descriptions, pricing, and shipping information to the product listings. With the products available for purchase, I leverage social media to reach my target audience and generate sales.


In conclusion, the journey from idea to product for the Pack Out system involves discovering, designing, prototyping, expanding ideas, and delivering them to the market. Through the use of 3D printing and thoughtful design, I am able to bring innovative and functional accessories to toolbox enthusiasts. Whether you're interested in toolbox reviews, Pack Out modifications, or the behind-the-scenes of my design process, I hope you find value in the content I create. Stay tuned for more exciting products and ideas in the future.

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