INTRO

For our boxes, Katy, Kaira and I decided to just make simple finger-joint cubes. Although we originally had the ambition to make some some of the more complex variations found on the template website. However, after hearing about certain horror stories from other groups, we played it safe.

Strategy

Kaira set up a file for us to test cut and check for both kerf but also if the thickness of our material was correct. This was really helpful as it allowed us to determine the optimal size for our finger joints. This size was 5mm x 10mm on the positive end and 4.9mm x 9.5mm. Using these numbers, we were able to setup a cut file for our box.

Finger joint test

Trying to figure out the design of the box was tricky at first but we modified the online template a little to incorporate our numbers and findings.

Cut design

Making

After doing rounds of test cuts and fittings along with rastering some images, we were able to confidently start cutting our pieces. Or so we thought. The piece of wood we found to cut our pieces out looked like plywood and probably was plywood but not the laser cutting kind. After 3 passes, the edges were beyond charred and the pieces were still not loose. We eventually realized the sunk-cost wasn’t worth it and began cutting on smaller pieces of plywood we knew would work. For next time, we’ve learnt not to assume anything about random materials we find in the OEDK and do a test cut before committing to the whole piece.

Layout File + Test cuts

For my personal design, I decided to make a dice. I thought the idea of a press fit dice would be funny as it would just shatter upon impact. This idea of a unusable dice was exemplified by the fact that I forgot how a dice works and that the number and face orientation actually matter. I had foolishly arranged the numbers in a sequential order on my file, making the end result inaccurate to an actual die. At the end of the day though, it wasn’t designed to be a usable die so I guess it was consistent with the overall theme…

cut die faces

The tolerance of the finger joints were pretty tight and honestly surprised me at how strongly they held. Putting together the first few pieces was relatively easy but I eventually needed to use a rubber mallet to hammer the last few faces on. At the end, I was left with a surprisingly strong press fit box. Maybe it could be used as a dice, or an unfair one at the very least.

Dice BOX!

reflection

Having used the laser cutter in Anderson Hall, I thought the project would be pretty straight forward. However, I know now that getting laser cut finger joints to fit tightly without glue is not an easy task. Overall though, I liked working in a group and it made the process more streamlined and easy. I was also able to apply these skills to make a mold box for another project I was working on.

Cost breakdown, total = $76