Add adjustable Gridfinity floors for transport boxes

[richardsolomou]

Problem

A Gridfinity insert fitted inside a transport box only provides one usable floor, leaving vertical space above shorter miniatures unused.

Why: Existing miniature holders and the bottom box insert should remain ordinary Gridfinity cargo. Users need movable extra floors without printing another base or a freestanding rack.

Changes

• Add a Box floors generator with assembled and support-free print-layout previews.
• Default to a 7×5 IKEA SAMLA setup with two upper floors; further identical floors are optional.
• Seat four hollow height rails in printed corner shoes beneath the existing insert without consuming Gridfinity cells.
• Provide physical 7mm or 14mm floor positions, reusable locking pins, and no purchased hardware.
• Use skeletal 42mm-pitch receiving lattices with integral puzzle joints inspired by GridFlock.
• Capture every floor in hollow perimeter rails seated in pinned shelf collars.
• Reinforce split rails with long internal sleeves while keeping deep structure outside the cargo footprint.
• Export every printable rack body as an independently selectable top-level 3MF object, automatically packed onto 180mm-class plates.
• Preview the existing bottom insert for context while excluding it from every export.
• Gate the production navigation and route behind the box-floors PostHog feature flag.

Risk

Medium. Insert edge shapes vary, so the corner shoes require a physical fit check. The analytical load screen is not a certified rating; filament properties, print orientation, layer adhesion, creep, assembly quality, and real transport shocks require physical proof-load and transport testing.

Verification

• pnpm check (244 tests)
• Geometry tests cover the shared Gridfinity profile, captured load-path engagement, rail/lattice deflection, pin and puzzle shear, collar bearing, exact floor pitch, unobstructed cargo cells, and maximum-size 3g design screen.
• Real gridfinity-box-floors-7x5-126mm-2-levels.stl generated as a closed Manifold mesh at approximately 1.44kg of PLA.
• Playwright coverage updated; Chromium is not installed in this runner.

Checklist

• Tests cover new or changed behavior where practical.
• Geometry changes are checked against a real export, not just the preview.
• User-facing behavior and physical limitations are documented in the README.

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Created with PostHog Desktop

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