For this project I designed and created an acrylic box using the OEDK laser cutter and a box template from makeabox.io. This article outlines the steps I took to create the box and some of the challenges I overcame.

Designing the Box

The first step was to design the box using Adobe Illustrator. I used makeabox.io to get the template for my 4’ box and then uploaded that pdf into Adobe Illustrator to add my designs. I was able to expand and trace the box from makeabox.io to make the edges the right size for the acrylic and get the right stroke width for cutting. I started my design ideas at first by reflecting on my summer in Colorado and how much fun I had camping and hiking in the Rocky Mountains. This idea evolved into a map and navigation themed box since another really strong memory I had of the summer was stargazing and consistently seeing the big dipper. This theme was how I chose the three images on my box – the Rocky Mountains map, the big dipper constellation, and a compass. Each image also has a different level of engraving intensity so I thought they would be good practice with the laser cutter. I also added a circular notch at the top of the box to use as a handle to open or carry the box easily.

Figure 1: Adobe Illustrator sketch of box

Getting the Right Box Dimensions

This process was kind of involved because the pdf from makeabox didn’t fit with the acrylic material very well so the pieces would fall apart. I tested with different forms of tracing the makeabox file to get the right size for the tabs so that the acrylic would not quickly fall apart when I placed the tabs together. In the image below you can see the results of these tests.

Figure 2: Testing different tab sizes and material widths

Getting the Right Machine Settings

Once I uploaded the Illustrator file to the OEDK computer, I started working on finding the right machine settings for the ⅛ inch acrylic I was cutting. The image below shows how I was testing settings for rastering with the compass image.

Figure 3: Practicing etching on the acrylic material

For cutting I found that 100% power 3% speed and 100% frequency worked well. 4% speed also worked but I liked how the 3% speed produced smoother edges on the acrylic. Then for rastering I used 600 DPI 50% power and 90% speed. This gave me a really smooth and clear raster that I was happy with. I started a little lower on the speed (around 75%) but I found that 90% speed worked well and was faster.

Figure 4: Settings for the laser cutter

Printing the Box

The acrylic came with a blue layer on top that had to be peeled off before engraving. The blue layer helps protect the acrylic from burning during the vector cut so what I did was leave the blue layer on for the vector cut then take the piece out and remove the blue layer on the side that I was going to engrave and then I ran it through the laser cutter just on the engraving setting. This is how I produced both the smooth edges and a clear engraving.

Figure 5: Creating the vector cuts with the laser cutter

Assembling the Box

Since I had done the testing process originally to make sure the pieces fit together it was pretty easy to put the pieces together at this point. I easily connected the sides and then the top and bottom of the box. 

I am really happy how the box turned out and I think that the acrylic material looks really neat and clean. Once we learn how to glue the acrylic, I plan to glue the sides together to make them sturdier.

Figure 6: The final assembled box

Cost Breakdown

A breakdown of the cost of the acrylic box. The quantity of acrylic was estimated to be 128 square inches for the six 4 inch x 4 inch sides of the box plus two extra sides that were used to test etching and machine settings.