This project was pretty straightforward, but it definitely reinforced my awe for modern machinery. The hardest part of this was getting the file formatted to print. We used a program to create the box (makeabox.io, because it allowed us to choose a kerf), which spits out a full six-sided box ready-made. I decided I wanted my box to be a little more functional for every day, so I made the top of each of the sides flat and only printed the bottom and the sides. Adobe Illustrator makes formatting text and images super easy, so it was easy to group text with the shape once I had built the shape out of the lines of the original file. The hardest part of getting the file set was getting rid of the rectangle that came with the imported Sid Rich logo because it was like a layer and three groups deep. Here’s the final file I ended up using. (It’s a screenshot of a preview, I apologize for the resolution.)

 

Before printing though, I executed an unsuccessful Kerf test that gave me a kerf that was way too big, and thus the box fit too tightly. I had to use a mallet to get the first version together, and it almost worked! Then, four of the tabs broke on the final side. It still fits well enough to use as a pencil box at least, but this is not my final submitted version.

     

Once I got a working kerf value from a classmate (all hail collaboration), printing was easy. I chose a value of 35 for the speed to find a good balance between text and deep engraving at 600 DPI, because the laser had to engrave through the tape as well. Here’s a test cut I did with the speed at text engraving (speed of 50) that I didn’t end up using because you couldn’t make out the small text on the bottom of the logo. Next to it is the final version that I DID use- the contrast with the engraved part is much more distinct. 

     

Once I nailed down the kerf values and settings, here’s the final result!

 

       

 

 

 

 

 

 

 

Cost Analysis:

Because the laser cutter is open-access (after training) and wasn’t purchased specifically for this box specifically, I’m not including that in my cost analysis.

For two boxes of 5 sides and a kerf test, roughly a 16 x 16 piece of 3/16″ plywood was consumed. A 24″ x 24″ piece of 0.25″ plywood is $8 from Home Depot. I spent about 3 hours in total on this, so at the minimum wage, the labor cost is about $22. Overall, this box cost $30 to make.