This week, I tackled the laser cutter in order to create my wooden box.
Starting off, I used the 2D drawing generated by en.makercase.com, as suggested. The setting I chose (shown in the figure below), was to use a finger size of approximately 0.642 and a kerf of 0.008.
I measured my wooden piece with a digital caliper, and entered the custom thickness (0.2449 in). After these changes were complete, I exported and opened the file in Adobe Illustrator.
Makercase box specifications
Using Illustrator, I made some customization to the front and back faces of the box, by adding my name and course number along with some nature-esque decor, as well as the Rice emblem on the opposite facing side. I also made sure that the outer lines of the box were set to ‘Stroke’ (width of 0.072 in) and the illustrations/text was ‘Fill’. This allows the laser cutter printing software to easily recognize which parts of the file to cut and etch.
Adobe Illustrator finished file
After sending the .ai file to the Epilog Laser Cutter printing application, I oriented the cut parts to the upper left corner of the frame. Then, I made sure the power and speed settings matched the ones suggested on the instructions/guidelines near the laser cutter (see print settings in the figure below).
Epilog print window settings and configuration
I used the trace feature of the laser cutter to ensure that the placement of the weights was appropriate and out of the way of the cuts. Then, after verifying that the laser was the correct distance from the wood, I closed the lid and clicked ‘Start’ to watch the magic happen.
Weights placement in laser cutter
I watched the laser cutter etch the text and graphics first, and then begin cutting out the pieces of the box. During this time, I noticed that the laser cutter didn’t actually cut some of the top lines of the first row of faces of the box, it skipped over those areas. However, it fully cut out the second row of the box faces.
Top lines didn’t get cut in the first row. Second row worked perfectly
I checked the file again, and it seemed correct. I couldn’t identify the issue. So I tried to re-cut only the first row of the box faces (see print settings below), and this time it worked!
Epilog print settings to re-try cutting first row
Now, I had all the faces of the box ready for assembly. It required some maneuvering, because it was quite a tight fit, but I was very happy with the finished result!
Partial box assembly (halfway done!)
Here are the front and back faces of my final assembled box!
Proof of clean workspace:
Cost Analysis:
| Cost | Price | Source | Quantity | Total |
| ¼’’ plywood (2 x 4 ft) | $14.94 | Home Depot | 1 | $14.94 |
| Laser Operator (in Texas) | $18.54/hour | ZipRecruiter | 0.5 | $9.27 |
| Machine Time | $50/hour | SALasers (Pricing Guide) | 0.5 | $25 |
| Total | $49.21 |
