I designed my box to look like a dice. The patterns of the circles for each face were relatively simple to replicate; the more difficult task involved accurately positioning the faces in relation to one another. The template for the laser cutting is shown below.
I worked with Daniel and Fed to find the perfect settings for the laser cutter. All of us decided to use wood covered with painter’s tape to minimize charring on the surfaces of the box. 90% power, 10% frequency, and 4% speed worked well for the vector cut, the test pieces we cut falling right off without further post-processing needed. Next, we tested the engraving based on the sample in the OEDK; 40 percent power and speed was a good balance of depth and char for us. However, finding the right kerf ended up being very time-consuming. We printed out a pattern similar to the one in the assignment (shown below), measuring a kerf of approximately 0.013”. However, after we cut two edges of the box to test the fit, we realized the kerf was too large. After trial and error, about 3 or 4 rounds of it, we found that 0.004” worked the best.
After getting the settings, the cutting out of the final design went well. The pieces pressed fit together with a little force and stayed in place. Here is the final product:
Cost Analysis:
Cost of Labor:
2h * $7.25/h = $15
Cost of Materials
3 ft * $0.12/ft = $0.36
$16.99/20 pieces = $0.85
The total cost of materials: $1.21
Cost of equipment:
Free rental at Harris County Public Library
Total Cost: $16.21
