Development of a Modular and Portable Tool Storage System

Post by: Tobias Larsson
10th August 2026
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Reducing wasted motion and improving workflow through modular and portable tool organization

This project explores the development of a modular and portable tool storage system designed to improve workflow efficiency in small workshops. By combining stable docking with portable tool modules, the system reduces wasted motion and enhances organization. The result is a functional prototype that demonstrates how engineering principles and Lean concepts can be integrated into practical product design.

Programme: BSc Mechanical Engineering

Course: BSc Thesis

Semester: june 2026

Corporate partner: –

The Challenge

This project addresses the challenges faced by users in small workshops, hobby environments, and educational labs where tools are frequently used and reconfigured. Existing storage systems often require users to walk back and forth to retrieve tools, creating interruptions and inefficiencies in the workflow. In addition, many solutions lack stable interfaces, leading to mechanical play and poor organization over time.
The design challenge was to develop a system that combines flexibility with mechanical stability, while enabling tools to be moved as a grouped module to the work area. The goal was to improve workflow efficiency, reduce wasted motion, and create a more structured and reliable storage solution.

The Solution

I designed and built a modular tool storage system that combines stable docking with portable tool modules. The system consists of a wall-mounted base unit and interchangeable modules that can be easily detached and taken directly to the work area.
The key innovation is a hybrid design where load-bearing functions are handled by steel components, while 3D-printed parts provide geometry, flexibility, and customization. By integrating principles such as positive retention, poka-yoke, and Lean workflow optimization, the system achieves both mechanical stability and ease of use. A functional prototype was developed and tested under realistic conditions to validate the concept.

Impact & Results

The solution improves workflow efficiency by reducing the need for repeated tool retrieval, allowing users to bring a complete set of tools directly to the work area. This can significantly reduce unnecessary movement and interruptions during tasks, particularly in small workshops where space and organization are limited.
In testing, the system demonstrated stable performance under a realistic load of approximately 3 kg and repeated handling cycles without unintended release, confirming its functional reliability. By enabling modular organization and reuse of components, the design also supports reduced material waste compared to fixed, non-modular storage systems.

Prototyping & Testing

Multiple physical prototypes were developed using FDM 3D printing in PLA, combined with standard steel components for load-bearing functions. The designs were created in Autodesk Inventor using a parametric CAD structure to ensure compatibility between modules and base units.
Prototypes of key concepts were tested through practical handling, docking, and stability tests, including repeated coupling cycles, manual shake tests, and static loading with a fully equipped module (~3 kg). These tests were used to evaluate usability, structural stability, and robustness under realistic conditions.
A key finding was that purely 3D-printed load-bearing geometries showed weakness due to material anisotropy, which led to the adoption of a hybrid design where steel components carry the main load. This significantly improved stability and eliminated the observed deformation issues.

Partner Feedback

The project demonstrates a well-structured engineering approach, particularly in how theoretical concepts such as mechanical interfaces and additive manufacturing limitations were translated into a functional prototype. The iterative prototyping process clearly shows an understanding of real-world constraints. (supervisor)