Laser cutting is a very satisfying experience and an essential prototyping skill. To begin my laser cut box, I created adobe illustrator files using https://en.makercase.com/#/.
To fill out these parameters, I followed the instructions to create a 4x4x4 box and changed the edge joints to finger joints. I adjusted the finger size to be 0.708 as suggested by the instructions. I also used calipers to measure the width of my wood. After inputting these parameters as shown in Figure 1, I clicked “Download Box Plans.”
Figure 1: Creation of box plans
After this, a menu popped up to allow me to adjust the kerf to 0.008 inches which was the best number according to the teaching assistants for the course. See how I adjusted this in Figure 2. Finally, after all this, I downloaded the SVG files.
Figure 2: Adjusting kerf and downloading box plans
After downloading the plans, I dragged them into adobe illustrator on a 40 (w) x 28 (l) canvas to match the size of the laser cutter bed. Next, I used shape builder to isolate each shape as shown in Figure 3.
Figure 3: Using shape builder
Next, I edited each shape to be unfilled and made the outline of each shape 0.001 inches to ensure that each shape would be cut. I deleted all the labels and added my own name and Rice University crest on the front and back face of the box respectively as shown in Figure 4.
Figure 4: Editing the box laser cutting files
I then focused the laser cutter and began by cutting out 2 interlocking pieces to assess the fit as shown in Figure 5. Once confirmed, I cut out the remaining 4 pieces of the box as shown in Figure 6.
Figure 5: Assessing fit of finger joints
Figure 6: Cutting out box pieces
After cutting all 6 pieces, I assembled the box as shown in Figure 7. When finishing up, I ensured the scrap wood and weights were put away in the correct location. Figure 8 shows a picture of my clean workspace.
Figure 7: Finished box
Figure 8: Clean workspace
Below is a cost summary for the laser cut box:
| Cost Type | Cost | Price | Source | Quantity | Total |
| Materials | ¼” plywood 2x4ft | $14.94/sheet | homedepot.com | 1 sheet | $14.94 |
| Labor | Laser Cutter Operator | $20/hour | ziprecruiter.com | 1 hour | $20 |
| Overhead | Facility Cost (Machine Time) | $15 – $30 per hour | accrurl.com | 1 hour | $30 |
| Design | Prototyping Engineer (me) | $0 (free) | Myself | 1 engineer | $0 |
| Iterations | $0 (no iterations required) | Myself | 0 iterations | $0 | |
| Misc. | Waste and Scrap | $0 (scrap recycled for other student use) | Myself | 0 disposal fees | $0 |
| Total | $64.94 |
