This project was a reprieve from the wooden crate project, which took an extremely long time due to a combination of router difficulties and a manual re-creation of the intended routed design. While I came in with some familiarity with the laser cutter, I had little experience with the newer device at the OEDK.
These two factors led me to choose the beginner level assignment, though in the future I may return to either of the higher levels as they are far more functional.
Like most, I started with determining a reasonable estimation for the kerf by cutting a sample path so a measurable 10-cut gap could be made. Ultimately my estimation came out to 0.0015″ (0.015″ gap per 10 cuts adjusted to one cut).
From here, I performed a test cut and engrave in order to test a design I had in mind. Since the last box was such an ordeal, the Companion Cube would certainly be a more welcoming box-shaped object.
~1 square inch test engraving and cut.
Promising settings after a few attempts: cuts completely/cleanly but with a dark brown edge rather than a char. Little char on the face even with it being almost fully engraved as well
Implementing this design was not trivial, so it was a decent exercise in illustrator as much as it was a simple but fun design. This was in part due to an error in my approach from being accustomed to the older cutter. This laser cutter was more fickle with detecting strokes meant for rastering, which caused some failed initialization of jobs.
Original .svg design of the Companion Cube from Portal
Attempt to erase borders that I thought would look odd resulted in some interesting artifacts. Erasing/manipulating recognized points would delete or cover entire quadrants of the image
Eliminating fill allowed for easier removal of perimeter, thought it caused a failed job as the region was somehow recognized as both a vector and engrave cut. Was potentially due to differences from previous software. Cutting is so fast, predicted time was barely different in either case.
Fixing small asymmetry in the pattern before copying between faces.
Eventually switched over to fill-only, actually preferred the effect of the mostly engraved face flushed with the cut edges.
For the rest of the box, I used makercase.com, using the recommended .5 in finger size as I stayed close to the original/baseline size at 4.5″x4.5″x4.5″. Of note, the material thickness was non standard, at least following the websites conventions (around .2 inches, almost exactly 5 mm, which is still a standard size amongst vendors).
Final layout had the Companion Cube on the front, back, left and right faces so they wrapped around seamlessly. This left the two required features, the crest and nametag, to occupy the top and bottom.
Following a decent amount of trial and error…
Attempting a 3% faster cut led to a very nearly completed cut, can see very faint outlines of faces.
The box was completed in not too long, at least compared to other projects in this course thus far.
To be transparent, there were a number of issues that arose in the final piece, largely from attempting to remove cut-out faces a bit too haphazardly and arranging the faces too closely, causing bending and tearing while removing. These issues were small enough and the fit was naturally good enough that further processing felt like it could damage the aesthetic or warp some edges/teeth. Sanding down the edges was not desirable since it was not wholly necessary (little char) and the lighter edge would look as though it was part of the negative pattern in the engraving.
Examples of chipping and peeling, due to more resinous engraved faces alongside more closely packed corners for cuts and tight placement on cutting bed.
Cost Analysis
Plywood
In total, 2 sheets across iterations approaching area of 1 board = $16
Home Depot: Underlayment (Common: 5.0 mm x 4ft x 4ft)
Labor
3 Hours at $20 an hour = $60
Laser cutter rental as low as $15 per hour * 2 hours = $30
Total Cost (counting labor, estimating tools) = $106
Looking Forward:
I do intend to complete at least the intermediate level of this assignment as well when it is not sandwiched next to another. Some ideas of mine for the advanced level range from a set of stacking, almost cylindrical capsules using living hinges to a sort of cabinet, essentially containing 6 mini website-buildable boxes within a compartmentalized box similar to the intermediate assignment.
For me, this exercise was a good first test of the new equipment as it had both some functional differences to previous equipment but allowed for incredibly rapid iteration (similarly sized personal projects on the older laser cutter would take upwards of an hours vs the ~22 minutes for this box design), so I’m far more excited to use it for the midterm project and a revision/advancement of this one.
