Description

This lessons will expand on lesson 2 by introducing the use of online, Parametric (parameter or variable driven) tools to create an flatpack boxes based on specified measurements. Parametric tools allow the dimensions of a file to be modified or adjusted while allowing certain dimensions to remain constant Parametric methods really complement the dynamic nature of Digital Fabrication.

We’ll be using Boxmaker to create a custom sized, press-fit box that be further personalized with graphics and text. These boxes make great desk organizers, tool boxes, gifts, or for any occasion where you need a box of a specific size.

1. Open Boxmaker

We’ll use an online generator called Boxmaker to do most of the work for us, simply open http://boxmaker.connectionlab.org/ in your browser to get started.

2. Customize + Download Box file

In Boxmaker, specify the preferred units and dimensions for the box you’d like to create, the size of the box is only limited by the size of the laser you have access to. It’s important to measure and verify the thickness of the material you plan to cut the box from, because this will affect the dimensions of the features that hold the box together. Once you’ve entered in all the correct data, press “Design It!” to generate and download a PDF version of your box.

3. Personalize Box (*optional)

The PDF file from Boxmaker is ready to be sent to a laser cutter as is, but we can use Adobe Illustrator to personalize it. Open Adobe Illustrator, and select File > Open… (Ctrl + “O”) to bring up the File Open dialogue. Locate the PDF you downloaded from Boxmaker in the previous step, and click the Open button.

Use the tools covered in Lesson 2, like the Shape Tools, Text Tool and File > Place… (Ctrl + Shift + “P”) to add custom text, shapes and images to the faces of your box. You can also use Shape Tools like the Rectangle Tool to add custom cutouts and holes.

4. Configure File for Laser Cutting

Once you’re happy with the card’s layout, the file is nearly ready to be sent to a Laser Cutter. Different services and machines may have different settings, so it’s worth contacting your laser cutting service to ensure you’re making a compatible file.

For example, at Toronto Laser Services we prefer:

Stroke Width: Use the Selection Tool from the Main Toolbar (“V” on your keyboard) to select the outlines of our box faces, you can click and drag out a selection box to select multiples. Change the Stroke value from 1pt to 0.0125”, which will specify it as a hairline.

Stroke Colour: With the outlines still selected, double-click the Stroke Colour indicator on the right, and use the Color Picker dialogue to change the stroke colour to red. You can either change the value of R, G, and B to: 255, 0, and 0 or enter “FF0000” into the “#” field. The “#” field signifies the Hex field, which is simply another notation of RGB colours. You’ll also need to do this to any holes or cutouts you added to the box.

When you’ve verified all the settings are correct, use File > Save (or press Ctrl + “S”) to save your file. Give it a meaningful filename which will help you find the file again.

5. Convert Text to Outlines + Save as Cutfile

If you added any text, use Select > All (or press Ctrl + “A” on your keyboard) to select every object in your file. While all the objects are selected, use Type > Create Outlines (or press Shift + Ctrl + “O”) to convert all of the text objects into shapes.

Now use File > Save As… (or press Shift + Ctrl + “S”) to save the file with a different filename, we suggest adding the word “-outlined” to your filename to keep things organized. This way you keep your original design file with editable text, and also have an outlined file that is ready to send to the Laser Cutter.

6. Send files to Laser Cutter

Laser cutting is available online through cutting services, and locally through schools, makerspaces, public libraries, and other facilitators. Use a search engine to locate the most accessible laser cutter to you, and be sure to consider the turn-around times and associated costs.

If you have any difficulty connecting with a facilitator, don’t hesitate to contact us at Toronto Laser Services. The shop is located in Toronto’s west end, in an open, safe, TTC / wheelchair accessible location; and ships globally.

When you’ve contacted a facilitator or fabrication space, they will let you know about their preferred process. At this point you you’ll need need to specify or provide the material you hope to use, as well as your “outlined” file from Step 7. You’ll also want to specify how many cards you’d like to have cut, though it’s generally a good idea to do a test cut of any file you haven’t cut, before doing many to ensure there are no adjustments that need to be made to the file.

7. Post Processing/Assembly

Depending on the material and laser cutter used, when you receive you box pieces back from the Laser Cutter, it may be ready to assemble, or require minor post processing. Woods sometimes get charred, sooty, or oily which can be cleaned up with quick sanding. Plastics like acrylic may have a protective film on them that needs to be removed.

Once the parts are ready, assemble your box! If you measured the material thickness accurately, the box should stay together without the need for glues or adhesives. If the box seems a little loose, use a small amount of glue to finish assembly. By adjusting the settings in the Boxmaker tool, you can adjust the settings in so no glue is required.

Advanced

Press Fit Boxes | Fablab Amsterdam (without generator)
http://fablab.waag.org/archive/press-fit-boxes

Parametric Flexbox by bdahlem - Thingiverse (without GUI)
http://www.thingiverse.com/thing:17240

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Task

Now that you’ve got the files all setup, be sure to get your box made and assembled! How well did it go together? Are there are measurements that need to be tweaked?

Share your response to "What are you going to make next with a laser cutter?"

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