Hi!!

Step 1: Testing the Kerf & Getting the Fit Right

I started my tight-fit box assignment by first figuring out the kerf of the wood. To do this, I used a kerf template on Canvas and followed the standard calculation method. My initial kerf measurement came out to 0.008 inches, so I moved forward with a test cut to check both the fit and the engraving quality.

For engraving, I tested M2 settings with 40 power and 40 speed, and I really liked how the images turned out. Since this was a finger joint box, I also experimented with vector speed increasing it from 3 to 6 helped reduce burn marks along the cut edges.

Quickly realized that the kerf was not enough as the box was coming apart. So I went in again and designed another one with 0.007 inch and this burnt my box too.

Finally, with the help of Katherine Sammy who was really nice to take some time out and help me navigate we finally decided to go with 0.0078 inches for the kerf measurement.

The Box fit together well and this was perfect for my final box.

   

Step 2: Preparing & Cutting on the Laser Cutter

I initially started my test cuts on the M2 laser cutter, but when I went to cut all six sides of my final box, I ran into issues the laser was engraving my vectors instead of cutting through.

At this point, I was advised to switch to the Fusion Pro cutter once it became available. Since I had to redo all my settings, I decided to just follow the laser cutter room charts for engraving and vector cutting. I set up my box file and sent it to cut keeping my fingers crossed.

 

Step 3: Assembly & Final Thoughts

After cutting, I popped out all the panels and started assembling my box. The fit was perfect for my standards, and I was really happy with how clean the cuts were. There were some minor engraving inconsistencies, but I actually liked how they turned out, so I decided to keep them instead of trying to rerun the engravings.

I would have liked to experiment more with rerunning some engravings to fine tune the results, but my laser cutter booking was ending and others were waiting to use the machine. Overall, I was super happy with my box and how smoothly everything fit together!

Cost Breakdown

• Time: $30.00
  • 3 hours → $10/hour
• Materials: $3.00
  • 1/8” thick 48×24 inch plywood
• Machine Rental: $180.00
  • Estimated $60/hour for 3 hours

Total Cost: $213.00

Final Reflection

This project was a huge learning experience with laser cutting, from kerf testing to troubleshooting machine issues. While I had to switch laser cutters midway, it was great practice in adapting and problem solving. Now that I’ve nailed the basics, I’m looking forward to experimenting with different materials, engraving techniques, and more complex designs in future projects!

Clean workspace