Stack, Nest, Sort: The Sizing Math

Stacking rings, nesting boxes and shape sorters look like design problems and are arithmetic problems. Choose two or three numbers, apply the rule, and the drawing writes itself.

What is inside

• Arithmetic against geometric ring series, both worked from the same endpoints
• Why a constant ratio reads as even to the eye and a constant step does not
• Sizing the peg from the stack, and the length at which a loose peg stops being a small part
• Nesting boxes built outward from the smallest, so the walls cannot eat the interiors
• Why 1.5 mm of clearance is not generous once seasonal movement is computed
• Tolerance stacking across a nesting set, and how to stop it accumulating
• Shape sorter clearance scaled to how many orientations actually fit
• Why chamfering the holes is the single largest improvement available
• Sizing solids so every loose piece clears both safety templates
• Palmar against pincer grasp, and why pieces are bigger than they look

Format

• 6 pages, A4, PDF
• Delivered as an instant download after purchase
• Print at 100% with scaling off — several drawings are reproduced at true size
• No physical item is shipped

Please note

This is a design guide, not legal advice, and it does not substitute for testing. Regulatory figures are cited to their source so you can verify them against the current text.