This week we were tasked with creating a laser cut box to practice both our vector cutting and laser engraving skills. Initially I shot for the stars by attempting to tackle the proficient level assignment to make a compartmentalized box to display future projects. But, as I quickly found out, my Adobe illustrator skills needed some work and with my other building up to midterms, I unfortunately didn’t have the time to devote to designing a custom box. I regrouped and followed the steps to make a 4in x 4in box instead.
The kerf value is a little too tight, resulting in edges splintering slightly as i pressed them together.
After designing the box in illustrator and adding some details to be engraved like my name and my college’s (Baker) crest we changed the stroke thickness on the lines we wanted to be vector cut to 0.072pt. I specifically adjusted the kerf values to ensure a tight press fit on the box. And while the final product was a little tighter than expected, it still worked great and I was pleased with the results. We first test cut some 1in x 1in squares to adjust the vector cut speeds and power. Once we found the settings that cut through with minimal laser burn, we sent the files to the laser.
After watching Benji’s box being cut out, I stepped up to use the laser cutter. The only issue that arose while cutting this box out was that the laser was a tiny bit too fast so the pieces needed to be pushed out of the stock wood by hand. In the process I tapped it out a little too aggressively and the piece went in a small crack between the laser bed and the side wall of the laser cutter (whoops). This is where most patience was required. After almost three hours troubleshooting the laser cutter (sometimes the parts would only engrave and not vector cut) The only thing I wanted was a complete product. I ended up going home with a 5 sided box and I couldn’t help feeling a little disappointed. After some assistance from the lab assistant on staff that next day, we lowered the bed of the laser cutter enough for me to stick my hand in and grab the final side. Once I tapped in that last side (with a little persuasion from a rubber mallet) I had a completed laser cut box!
The Baker crest got a little dark as it was being engraved. This is a stylistic choice, but I wanted it to be a little lighter
I have laser cut in the past for some projects, but this was my fist time assembling the 2d shapes into a 3d object. It’s so exciting the possibilities that arise from this technique and we’re already brainstorming ways to use our newfound laser cutting skills to make our midterm project!
Ladybug dice! I made sure to make the opposite sides add up to 7!
Having to hammer this box together resulted in the sides splintering. I wasn’t happy with the results so I got back to work in adobe illustrator to make a new file. I came up with the idea to make a giant dice with bugs for the dots. I love playing board games and this will be an exciting way to spruce up the games. I also think bugs are underrated, so I chose to feature them in by box design. I made the file and sent if off to print, but when in the settings window for the laser cutter, the laser only was engraving the file. I troubleshot this issue for a couple hours. First I tried remaking the file in case the download from the box maker messed up. When this didn’t work, I used Benji’s Adobe Illustrator account in case I has a setting clicked that I messed up. Finally I changed the images from pngs to svgs. This did the trick for me. I made a dice with ladybugs as the dots and sent it off to be printed.
Final Ladybug Dice Box!!
Cost Analysis:
Material costs:
200 square inches of OEDK stocked 1/4in wood – $10 for a 2’x3′ sheet so $2.32 for what I used
(96 square inches for each box and 8 inches from offcuts)
Total (material cost) – $2.32
Labor costs:
I spent 3 hours on the computer designing the box, 3 hours operating and troubleshooting the laser cutter. If you assume an average salary for a laser cutter designer and operator of $15.43, This box cost $92.58 in labor.
Total: This crate costs $94.90.
