Making deep shelves work harder

The brief

The client wanted shoes stored upright and visible inside deep shelving. The brief called for a base tile, angled support and front rail, designed around PLA printing on a Bambu X1-C. A useful model had to accommodate different shoe profiles while remaining slim and adjustable.

How it went

Turn the concept into measurable constraints

I worked from sketches and visual references, then measured three sneaker types to check the proposed spacing. I developed the base, supports and front rail as separate parts and shared intermediate views before final edge treatment.

Compare alternatives before rebuilding

When taller shoes conflicted with the layout, I tested changing the support angle from 75° to 60°. My CAD comparison showed a 33 mm structural offset for only about 7 mm of useful clearance. I recommended increasing the short side of the base to 9 inches instead; the client agreed.

Refine the assembly

I widened the front rail after checking shoe placement, reduced unnecessary bulk, and incorporated edge pegs and sockets so adjacent tiles could connect. I delivered component files and a consolidated STEP model.

Listen to the physical prototype

The client later reported that the concept worked, but the support pegs were too tight to remove comfortably. I proposed smaller fit-test samples rather than another complete print. That work became a separate follow-on contract.

The decision I would defend

The important decision was to change the footprint after comparing actual clearance gains, rather than assume that a steeper or shallower support would solve the problem.

Outcome

The client approved the first delivery, left a public 5/5 review and later shared physical prototype photographs. The prototype validated the overall concept while revealing a real-world fit issue to refine.

Delivered

• Base tile, support panel and front rail component packages
• Modular and unmodified base variants
• Consolidated STEP model
• Progress views and prototype revision recommendations

Scope and limits

This case documents the first prototype. A removable production fit and commercial sales are not established by the record. Later tolerance samples belong to the separate second phase.