How to Make Custom Milwaukee Packout Inserts with a 3D Printer

Published 2026-02-24 by Chris Winland

If you own a Milwaukee Packout system and a 3D printer, you already have everything you need to create perfectly fitted custom inserts for every tool you own. No more rattling drill drivers, loose socket sets, or wasted space.

The typical approach involves learning Fusion 360 or TinkerCAD, manually measuring each tool with calipers, modeling the cavity, and then hoping it fits after a multi-hour print. Most people give up after the first attempt. Others spend $20 to $50 per insert buying pre-made STL files that almost fit their tools.

There is a faster way. You can convert a photo of your tool directly into a 3D-printable insert file that drops right into your Packout case.

What You Need

Step 1: Photograph Your Tool

Place your tool flat on a sheet of paper. The paper serves as a size reference so the software can calculate exact real-world dimensions. Take a top-down photo with your phone. Try to keep the camera directly above the tool to minimize perspective distortion. Good lighting and a contrasting background help the edge detection algorithm work more accurately.

Pro tip: If your tool has a complex shape (like a ratchet or pliers), photograph it in its closed position. The outline will be cleaner and the resulting insert will hold the tool more securely.

Step 2: Upload and Trace

Upload your photo to TracetoForge. The app automatically detects the paper boundaries and the tool outline. You can fine-tune the trace with click-and-drag controls if needed. Set the real-world dimensions (the paper size handles scaling automatically).

Step 3: Configure for Packout

Select "Custom Tray" mode and set your tray dimensions to match your Packout case interior. For example, the Milwaukee 48-22-8435 Compact Organizer has an interior of roughly 390mm x 245mm. Set the wall height to match your desired insert depth (typically 25-40mm depending on the tool).

You can also add finger notches so you can easily grab the tool out of the insert. Position them by clicking on the 3D preview.

Step 4: Add Multiple Tools

One of the biggest advantages of using TracetoForge over other insert generators is multi-tool support. You can add multiple tools to a single tray, each with independent cavity depths. A shallow screwdriver sits at 15mm while a bulky impact driver gets 35mm, all in the same insert.

Step 5: Export and Print

Preview everything in full 3D, then export as STL or 3MF. Slice it in your preferred slicer (PrusaSlicer, Cura, BambuStudio, OrcaSlicer). Recommended settings:

Why Not Just Buy Pre-Made Inserts?

Pre-made Packout inserts from Etsy, Gumroad, or specialty shops like Vork Design and Kaizen Inserts range from $10 to $50 per insert. They work well for common tools like the M18 Fuel drill/driver combo. But if you have unusual tools, mixed brands, or a specific layout in mind, custom inserts are the only way to get a perfect fit.

With a 3D printer and TracetoForge, the cost per insert drops to roughly $1 to $3 in filament. And you can iterate as many times as you want. When you upgrade a tool, just photograph the new one and print a fresh insert.

Packout Models and Interior Dimensions

Here are the approximate interior dimensions for common Packout cases. Measure yours to confirm, as tolerances can vary slightly between production runs:

For drawer models, you can also use Gridfinity inserts by selecting "Gridfinity Bin" mode in TracetoForge. Many Packout users combine a Gridfinity baseplate in their drawers with custom tool inserts in the larger cases.

The Bottom Line

Custom Packout inserts used to require serious CAD skills or expensive third-party products. With photo-to-insert tools and a 3D printer, anyone can create professional-quality custom inserts in minutes. Your tools stay organized, protected, and instantly visible.

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