1.Measurement and Preparation

The First step was to confirm the thickness of the material so that I could choose the correct finger size. The thickness of my wood piece was 0.18”. Also, I chose 0.52” finger size as there can be 3 or 4 fingers on each side. After checking the guideline of the machine, I chose to use the laser setting of 80 power, 4 speed, and 10 frequency to cut the edge. Before I get started, I opened the vacuum and preset the machine.

2.Test the Kerf

Because there is a kerf of the laser burning, we need to have extra spaces on the document to ensure that each wood piece can be connected as we expect. Using the file for the course, I laser cut a piece with 10 kerfs. The initial length is 3.71” in the document, and after laser cutting, the remaining is 3.50”

Kerf size = (3.71-3.50)/10 = 0.021”

So I chose the kerf size of 0.02” for extra spaces to inset the woods.

However, there was something wrong with my original wood board that it easily gets burned and becomes charred. So I gave up my first wood and chose another one. I knew that it is not appropriate to waste material, but I thought this is a necessary case.

3.Design the box and Trial Laser Cut

I created my own image on Adobe Illustrator. First I supposed the machine can print high-resolution picture, so I chose a picture of my best friend and tried to leave him on my box. However, 500 resolution cut was too vague to see details on his face. As I tried to increase the resolution, the estimated time cost became too long. Besides that, I clicked “split by color,” and because of the complexity of my friend’s face, the computer had no response. Hence, I gave up this idea can decided to engrave the Pikachu memes that I always use.

The good news was that the two cut piece can be tightly connected, which verifies my setting is correct.

4.Final Cut and installation

I adjusted my file and have the last cut of all six pieces. I forgot to change the width of the lines to change them into vector form, but that is not a huge problem because I noticed it and didn’t start until every setting is correct. After a 20-minute cut, I got my final pieces of woods. Then I installed them together.

5.Post Processing

I used 180grit and 320grit sandpaper to polish my box. It did not only makes the touch smoother, but also made my images on the box much clearer. Then I used pencil to blacken the cheek of my Pikachu so that it looks better.

work place before I leave:

Cost Calculation:

On Amazon:
12 pack of 18*24 plywood:$70
21 sheets of 180 grit sandpaper:$7
12 sheets of 320 grit sandpaper:$10

A wasted plywood + 1/3 of a useful plywood: 1.33 * 70/12 = $7.76
2 180 grit sandpaper: 2 * 7/21 = $0.67
1 320 grit sandpaper: 10/12= $0.83

Machine:
on lightobject.com
Laser cutting machine $120/h * 1h

Labour: $30/h *2h (Houston average wage)

In total: $189.26