This week, for the laser cutter project, I created a box with Sammy the Owl, the Baker Crest, and my name etched into it. In this blog, I document my journey through creating my 4”x4”x4” box.

To commence this product, I had to generate a box with the correct dimensions and the right kerf in mind to ensure the final product was a tight and flush finish. To do this, I first had to create a kerf box and calculate the kerf, which turned out to be 0.005 inches. With this information in mind, I could generate my AI file and upload it to the laser cutter.

Once I got to the laser cutter, I did a simple test with a square to understand the correct settings and to limit any chance of burning the wood. I figured I could now move on to the project, but I was worried about any mistakes I might commit since it was the first time using the M2 laser cutter. Although it provides more control than the M2 Pro, I was not as familiar as I wanted to be when using the M2. So I decided to cut one side with the name etched into it. It was one of the many issues I ran into. While etching my name, the machine went over it twice, resulting in a darker color, which I was dissatisfied with. After this, I attempted to remedy the situation by adjusting the settings and attempting with another image, and I encountered the same issue. I discovered this issue three times throughout the construction of this box.

Another issue I encountered was an incomplete cut of the wood. When I went over to pluck the pieces of wood out of the entire panel, I realized it didn’t cut through. But I thought I hadn’t moved the piece, so I decided to rerun the machine, and I was wrong, because I had ever so slightly moved it, resulting in an incorrect shape. Thus, I committed another mistake. 

Then, when I figured out everything, I decided to print another 6 in one fell swoop, feeling confident, so I printed them out. Everything turned out great. But when I assembled the box, I realized the box width was not accounted for and thus did not fit correctly, resulting in another failure.

But I quickly addressed this problem and finally constructed my box with a tight and flush finish. 

Picture of the clean working space.

Cost Analysis: 

Labor:

4 hours at Texas Minimum Wage = $29

Materials:

Wood: 2ft x 2ft = $8.30

Equipment:

Maker Bar: $50 a month=$1.67 per day

Total = $38.97

After many trials, I finally completed my project, with a final product I am happy with, considering the previous iterations of this project. This process displayed my lack of knowledge on Adobe Illustrator and how I could familiarize myself with this program. I greatly enjoyed this project because it significantly increased my experience and understanding of the laser cutter, which will be crucial for my midterm project and future endeavors in the OEDK. Even though it was very frustrating, this journey was well worth it.