This week’s assignment in ENGI 210 was to either simply cut a makeabox.io template using the laser cutter and assemble it or design, sketch out, and cut your own box plans with various dividers. I opted for the challenge and started early on my quest to complete this divided box.

I started by, of course, doing my research. I read all of the ENGI 210 Laser Cutting blog posts from last semester to gain incite and inspiration. From these posts, I learned the proper kerf to input into makeabox.io for the perfect snap fit (0.007″), the proper offset to assign free-handed cuts and joints (0.02″), as well as different approaches to designing the box (SolidWorks vs. Abode Illustrator).

I first sketched out my design plans on a piece of notebook paper, referring to the dimensions PDF for guidance. All dimensions are in inches.

I was then ready to draw! I took note of the preferred softwares across the various blog posts and decided to give SolidWorks a go due to the many complaints regarding Adobe Illustrator’s measurement capabilities. However, I soon realized that my knowledge for the program was limited, and I did not have the time or patience to master SolidWorks for this project. Back to Adobe!

I first went to makeabox.io and downloaded a 7.5″x11″x3″ box with a 0.007″ kerf. From there, I deleted the “roof” piece and started free-handing the various dividers in my box. I created these pieces by making rectangles and adding joints and cuts where appropriate. I overlaid different pieces to line up accurate align the connection components. Although previous projects had complained about the measurements in Adobe, I found that if I used the Grid overlay, it was easy to keep track of my alignment and proportions. About half way through my drawing process, I decided to do a test cut with cardboard to see if I was headed in the right direction. I followed the proper protocol for operating the laser cutter and adjusted the settings to safely and accurately cut cardboard.

I was very pleased with the outcome of my first test cut! I underestimated the size of the cut, and the cardboard piece I chose was a little small (as seen in two of the corners). Nonetheless, I knew I was in the clear to finalize my plans. After some additional copying, pasting, cutting, and drawing, I had my finished plans…

I added labels to each compartment, a name plate, as well as the Rice Owl logo for visual appeal. I initially cut out of cardboard again, leaving out the etched details, just to be sure that my added pieces fit nicely.

Success! Everything fit perfectly, so I went ahead and ran the same adobe file with the added details through the laser cutter with wood, instead. The only adjustments necessary were to change the settings on the laser cutter to properly cut 0.2″ plywood. 

Next, I removed the pieces from the excess wood. This process can be difficult if the laser does not completely cut through the wood. However, my pieces were all relatively easy to remove: a huge relief. I quickly sanded down any frayed joints and edges and was then ready to assemble!

I began by simply snapping together the dividers. I used a rubber mallet to secure the connections to their fullest.

I then snap-fit the dividers to the base of the box.

Next I connected the shorter walls of the box to both the base and the center divider.

By far, the most difficult connections were the large side panels. I had to maintain alignment of numerous joints and holes and simultaneously force fit the pieces using the rubber mallet. After a good ten minutes of pounding away, I got one side locked in place.

The last piece was a battle. I realized that the holes in the final side panel that connected to the dividers were slightly too low for the respective joints. However, it was nearing midnight in the OEDK, and I was determined to make it work. I sanded down the joints a bit to see if I could get them to go, but ultimately I did have remove a nit of the wood using the Dremel. In the end, my box finally came together.

I mixed some saw dust and wood glue to fill the few gaps caused by filing down the joints on the final side.I definitely could have gone back into Adobe and lowered the holes on the side panels to improve the fit and possibly avoid the use of the Dremel. There are also small gaps between some of the dividers due to inaccurate measurements. I made Adobe Illustrator work but not perfectly. Free-handing measurement-based designs almost guarantees some visible margin of error. These gaps are not super noticeable, and overall, I am happy with my final product. Here is a fun side by side of my cardboard and wood models.

I would argue that I successfully divided and conquered this box! Onto the next quest. It is looking like we are headed south to the plasma cutter for our future adventures. Stay tuned!