For this ENGI 210 project, we were tasked with making a laser cut box to demonstrate proficient use of the laser cutter. After being given a sheet of wood, I first set out to find the right amount of kerf to use for the finger joints used in the box. This posed the first major challenge for this project, since I had to use multiple kerf tests seen in figure 1 to get an accurate kerf measurement. Using smaller cubes to test kerf settings turned out to be the most effective method, and after some trial and error I settled on a kerf value of 0.0125 inches.
Figure 1: Various Kerf Tests Used
Next, I was able to start designing the box. I decided to input some creative flair in this step and model my box after an all-in-one desktop computer, shown in figure 2. This design also allowed me to experiment with a finger T joint to model the base and stand of the computer, which added some additional complexity to the overall design. To complete the look, I downloaded some computer related graphics to place on the box, such as the windows wallpaper and the computer IO. I was also able to implement the core requirements of the college logo and documentation text within the theme as well.
Figure 2: Sketch of Computer Box to be Laser Cut
After having a designed box in hand, I moved on to the laser cutter. I segmented the raster and vector jobs to occur separately, so I could test fit the box before going ahead with the raster. Figure 3 shows the vector job followed by the raster job being completed. I made a key mistake by forgetting to use painters’ tape while laser cutting, which would have minimized burn marks on my final print. I also ran into some issues with the fitment of the finger T joints, which required me to rescale and reprint the inserts to get a consistent fitment.
Figure 3: Vector and Raster Jobs Being Performed
Once all the pieces had been laser cut, I was able to assemble the box. Since I had done thorough kerf testing prior to printing, the box didn’t require any post processing. The final box can be seen below in Figure 4. As always, keeping a clean workspace was of utmost important, so I made sure to dispose of any scrap wood that could no longer be used in the dumpster behind the OEDK, and keep the ENGI 210 table clean after each use. Figure 5 shows the laser cutting being left cleaned and ready for the next person to use.
Figure 4: Final Box Assembled
Figure 5: Cleaned Workspace (Laser Cutter)
Finally, I have included a cost breakdown below as a reference:
| Item | Quantity | Estimated Cost ($) |
| 24 x 24 Inch Craft Wood | 1 Sheet | 5.00 |
| Painters Tape | 1 Roll | 4.00 |
| Labor | 8 hrs @ $10/hr | 80.00 |
| Laser Cutter Use | 1 hr @ $100/hr | 100.00 |
| Total Costs: | 189.00 |
