Introduction

Before this project, I had a good amount of experience in laser cutting wood, but never rastering or fitting pieces together without the help of an adhesive. This taught me the importance of planning ahead and using my time wisely. This also marked the first experience I had using the Epilog Pro laser cutter (at least a fully functioning one with all the perks and benefits).

Process

The task was to create a 4″ by 4″ by 4″ cube using no fasteners or glues. Essentially only being friction fit.

The first of my tasks was to figure out the kerf using MakerCase. The kerf is the thickness of the laser used to cut and how to take that into account on the box. Traditionally, the class uses a file that allows the measurement of the kerf to be physically made. I could not find the file and made the mistake of not requesting it. [This comes up later.] Instead, I opted to make tons of test cuts of a 1″ by 1″ by 1″ box and see how snug the pieces fit together. 

 

 

 

 

 

 

After testing, I determined the best kerf was 0.007″. [Also not true]

Once that was done, the next step was to select the designs that would be etched onto the box. Since this box would be personalized, I decided to choose objects that represented parts of my identity.

After selecting the images, I made the SVG file having both cutting and etching lines. I covered my wood in masking tape to reduce charring on the surfaces of the wood. As I couldn’t figure out how to cut, then remove masking tape, then etch in one step, I decided to import two SVG files, one for cutting and one for etching.

 

 

 

 

 

 

 

 

 

 

Once the box was cut and etched, it was press fit and fit fairly snugly. One issue I had afterward was the finger joints being too long and not giving the corners a smooth finish. This was a result of the flawed kerf finding system I used. 

Overall, the box came out great and I am proud of how it turned out!!

successes and failures

Etching was a new skill I had never used before. So naturally I made a couple of mistakes along the way. For one, I thought DEEP ETCH on the computer meant that its etches would come out darker. Instead, it meant that it would cut all the way through, causing a mini fire. After testing etching with the Mexican Flag I was on my way. Another issue I ran into was aligning the etch with the square using my adjusted method for cutting and etching. At first, I tried cutting then etching, which resulted in the bottom cube.  Then, I decided etching then cutting was the move.

   

COSTS

Wood: 1/4″ 4’x8′ Plywood = $29.12 (Home Depot)

Time: 4 Hours @ $13/hour = $52

Laser Cutter, Adobe Illustrator, MakerCase provided

TOTAL: $81.12