I love the Catch-All Tray design by HD, but I found the connectors and plugs too loose for my needs, so I rebuilt the connectors and plugs from scratch for a more precise fit with tighter tolerances.

This allows the trays to be joined more solidly, allowing them to be moved/lifted without separating.

Since different printers have different levels of accuracy, I've redesigned the connectors with a few tolerance levels, that you can experiment with to get the best fit for your printer setup.

The tolerance levels are:

• 0.1mm (tight fit): best used when you want a permanent connection
• 0.13mm ("perfect" fit) - snug fit that is very solid, but allows for removal/reconfiguration if needed (I personally use this for the connectors)
• 0.15mm (loose fit): better for less accurate printers, or using a material with higher shrinkage than PLA.

Parametric / Configurable

The connectors and plug fit tolerance can be configured in Onshape to give a more precise match for your own printer settings if required.

Edit in Onshape.

Printing

These can be printed either standing or lying flat on the bed, but for better aesthetic fit with the original trays, print standing.