Mail sorting box
Move envelopes through incoming, action and filed groups without mixing unfinished mail back into the inbox. All files are free, including your customized plan.
Move envelopes through incoming, action and filed groups without mixing unfinished mail back into the inbox.
Three lanes map to three stages of mail handling and expose envelope tops for daily review.
For Someone processing household post at a desk. Default clear opening: 103 mm × 252 mm × 106 mm.
Adjust dimensions and stock ↓Measure before you start
- Measure the longest envelope and any outer document wallet.
- Measure the thickness of the busiest stage's bundle rather than a single envelope.
Tools and access
- A saw and guide for straight cuts
- A square, measuring rule and caliper
- Clamps suitable for the dry assembly
- A sanding block for accessible edges
Using this organizer
- Put new post in the incoming lane.
- Open and move each item to action or filed during a daily review.
- Empty the filed lane into long-term storage so active work stays visible.
What a useful result needs to do
- An envelope can move between stages without folding.
- The action lane can be identified and emptied independently.
- Paper labels remain readable with all three lanes occupied.
If the fit is wrong
- If the action lane overflows, process or split the backlog before adding more post.
- If one changing group needs more space, use the removable mail-and-device divider.
Your parts
| Part | Cut length | Cut width | Thickness | Qty | Grain |
|---|---|---|---|---|---|
| 345 mm | 115 mm | 9 mm | 2 | Along length | |
| 252 mm | 115 mm | 9 mm | 2 | Along length | |
| 327 mm | 252 mm | 9 mm | 1 | Unrestricted | |
| 252 mm | 106 mm | 9 mm | 2 | Along length |
Item allowance: upright envelopes (floor footprint) — 60 × 229 mm, plus 10 mm of handling space per axis.
A feasible cutting layout
Numbered cuts span their parent region. Coordinates use the sheet's top-left origin. Trim all four edges of each sheet you use first. Keep unused sheets whole. This layout does not claim the lowest possible material use.
Compare your stock choices
Try this same inventory with offcuts first and standard sheets first. Each result is a feasible estimate; the solver may miss a better layout.
Sheet S1.1
Cut sequence
| Cut | Parent region | Direction | Coordinate (mm) | First child | Second child |
|---|---|---|---|---|---|
| C1 | N1 | horizontal | 120 | N3 | N4 |
| C2 | N3 | vertical | 350 | N5 | N6 |
| C3 | N6 | vertical | 698 | N7 | N8 |
| C4 | N4 | horizontal | 375 | N9 | N10 |
| C5 | N9 | vertical | 332 | N11 | N12 |
| C6 | N12 | horizontal | 238 | N13 | N14 |
| C7 | N13 | vertical | 587 | N15 | N16 |
| C8 | N16 | vertical | 842 | N17 | N18 |
| C9 | N14 | horizontal | 347 | N19 | N20 |
| C10 | N19 | vertical | 587 | N21 | N22 |
| C11 | N22 | vertical | 842 | N23 | N24 |
Sheet S1.2
Cut sequence
| Cut | Parent region | Direction | Coordinate (mm) | First child | Second child |
|---|
Connections and machining
No grooves or notches are required. Cut the rectangular parts, then follow the connection details.
Put it together
1. Measure and mark
Measure the actual sheet thickness (9 mm in this plan). Mark front / back F, left / right L, base P and dividers D. Recalculate if the measured thickness differs. Measure the longest envelopes you use before cutting.
Parts: F, L, P, D · Start here2. Cut and label the parts
Follow the numbered full-width cuts in the cutting sequence, then subdivide each labeled child region. Keep the part IDs and grain arrows. Use the instructions supplied with your tools; this plan is not tool training.
Parts: F, L, P, D · After measure3. Dry-fit the outer walls
Front and back span 345 mm. Fit the 252 mm side walls between them. Check the outside footprint 345 × 270 mm and square the corners. The inset base is 327 × 252 mm; its underside sits flush with the wall bottoms. Total base clearance is 0 mm per axis (0 mm on each side).
Parts: F, L, P · After cut4. Assemble the base and walls
Prepare and bond the butt-joint contact faces using an adhesive suitable for your sheet. Center the inset base at z = 0 mm. Check squareness before clamping. For a clearance gap, verify the adhesive allows that gap; use zero clearance or revise the fit if it does not.
Parts: F, L, P · After dry-fit5. Position the dividers
Mark each divider from the inside face of the left wall. Place the first divider after 103.00 mm of clear space; repeat at a pitch of 112.00 mm. Glue the bottom edge onto P and both ends against F. Each compartment has 103.00 × 252 mm clear floor space. These are straight glued partitions, with no grooves or hidden fasteners.
Parts: D, F, P · After glue6. Cure, finish and check the fit
Follow the adhesive manufacturer's cure and handling instructions. Smooth edges and apply a finish compatible with your materials. Attach four self-adhesive felt pads under the base corners. Use removable paper labels rather than drilling an unknown label fitting. Use for light desktop items; no load rating is provided.
Parts: F, L, P, D · After divide
Materials and supplies
- Uses 1 standard sheet(s) and 0 existing offcut(s). Check your inventory before buying.
- S1: 1 of 2 used · 900 × 600 × 9 mm plywood (standard sheet). Unused stock stays whole.
- Four self-adhesive felt pads.
- Adhesive suitable for the selected sheet. Prepare according to the adhesive label and actual contact faces; no universal quantity or cure time.
- Compatible finish and abrasive. Choose for the actual material and intended indoor use.
Take the complete plan
Parts, stock, cutting sequence and machining CSVs, connection and assembly diagrams, a printable plan and editable JSON. No sign-up.
For PDF, open the print page and choose Save as PDF in your browser. Use A4 or Letter.
For light desktop storage. Geometry checked; physical assembly and durability untested. Follow your tool, sheet and adhesive instructions. Adhesive quantity and curing time depend on the product you use.