The goal of this assignment was to laser cut a box by using plans in Adobe Illustrator and to help us become more familiar with using the laser cutter. After spending tons of time on the hand built box, this homework assignment was a nice change of pace. Since I had no prior’s experience with illustrator, I chose the beginner option.

BOX 1:

I first used the website maker-case since it was simple and had the option to make a topless box.  I saved the file into illustrator the added a text box with the required information.

 

When this finished cutting, I thought I would be done with the assignment in less than an hour. I soon learned that I would have to try again. Maker case did not account for the kerf of the laser cutter so the finger joints were pretty loose.

To have the box actually hold itself together, I used wood glue and clamped it together overnight. When I came in the next day, the box was solid but I learned that glue was not permitted on the assignment.

BOX 2:

For my second box attempt,  I used makeabox.io since it had options for adjustable kerf and stroke width. This website did not have an option for a topless box so I had to make edits in illustrator make to top of the 4 edges flat. After cutting out this second design, the joints were noticeably tighter and I had to work more creatively to make them fit. While the links were much tighter than the previous attempt, one face was noticeably loose and would come detached if picked up from that side. Since other assignments were coming up, I decided to leave the box as it was for the time being.

BOX 3: 

Eventually I stopped pretending that this homework was truly completed and I took to the time to finally make it in a way that met the design goals. This time, Make a box was down, so I had to improvise and find a new site or make it myself.  Eventually I found a site called boxdesigner and I made sure to carefully measure the thickness of the wood and to do multiple tests cuts since the laser cutter had been inconsistent with its cuts in the past few days. When the box components were ready and I first attempted to assembly them, I was worried since it seemed like the open slots were too small for the finger joints and I might have to redo the box again. Luckily, Matthew told me this is how I knew my box would hold together tightly and it I lightly tapped the joints together with a rubber mallet, it would fit snugly. and luckily it worked.

Cost analysis:

1/8″ plywood, 24″ x 32″ (OEDK) $5.00 x 3 = $15

3 hours of work x $15/hour = $45

<1 hour of cutting x $12.73/hour for usage of CO2 laser cutter. = $12.73

https://fsmdirect.com/cutting/laser-cutting/75-co2-versus-fiber-laser-cost-to-cut-a-part

Total cost= $72.73

I would definitely not pay $72 for a box as simple as this but the cost would have gone down significantly if I was more careful with the details of material thickness and kerf initially.