Laser-cutting

Press-Fit Box

1- Set the parameters of the design from modefy - change parameters, set the width and hight of the box (200mm X 100 mm), set the kerf (0.2 mm), set the thickness (3 mm), and set the width of the tab (20 mm). 

2- Start a new sketch, draw a 2 point rectangle with the parametric dimensions

3- Sketch two construction lines, make sure they're at the middle of each rectangle lines. 

4- Sketch a 2 point rectangle inside the first rectangle (hole) on its side and set the dimentions (tab width - kerf) (Thickness) 

5- Repeat the previous step for another hole 

6- Set dimensions to constrain the design, the first hole is 20mm away from the center, and the second hole is 20mm away from the first hole

7- Go to sketch - Mirror, to mirror the two holes along the line, and then mirror the 4 holes to the opposite side as well. (the construction lines are used as mirror lines)

8- At the bottom, Sketch a 2 point rectangle inside the first rectangle, but don't sketch it on the side, sketch it 3mm (Thickness) away from the side and set the dimentions to constrain the design . set the dimentions (tab width - kerf) (Thickness)

9- Set dimensions to constrain the hole, make it 15mm away from the center. 

10- Mirror the hole along the line, and then mirror the 2 holes to the opposite side as well. (the construction lines are used as mirror lines)

11- Stop sketch, select the body and extrude a new component at 3mm or thickness 

12- We can mirror the new component by constructing an offset plane from constrcute - offset plane and setting it to the middle, and then selecting the component and creating a mirror for it.  

13- we can repeat all the previous steps for the rest of the sides, with a few exceptions:

  •  the dimensions of the 2 point rectangle with the tab (teeth) are (200mm X 94mm) or parametric (width X hight - 2*thickness), because the teeth has a thickness of 3 mm and we want the total dimentions of this side to be (200mm X 100mm)
  • Sketch a 2 point rectangle outside the first rectangle (teeth) on its side and set the dimentions (tab width + kerf) (Thickness) 
  • Don't forget to select the teeth with the body when you extrude it. 

14- For the top and bottom, repeat the previous steps with the following exceptions:

  •  the dimensions of the 2 point rectangle with the tab (teeth) are (94mm X 94mm) or parametric (hight - 2*thickness X hight - 2*thickness), because the teeth has a thickness of 3 mm and we want the total dimentions of this side to be (100mm X 100mm)
  • Sketch a 2 point rectangle outside the first rectangle (teeth) on its side and set the dimentions (tab width + kerf) (Thickness) 
  • Don't forget to select the teeth with the body when you extrude it. 

15- Assembly the 6 sides by rigid joints. Go to Assemble - joints , then select an origin point on a teeth and then on a hole and then, they will join. repeat this for the rest of the sides. 

16- once the box fits, go to each sketch and trim any construction lines, lines around the holes. Save all sketches as DXF files to be printed on a laser cutter.

17- Use the laser cutter software to setup the sketches. Make a copy of each sketch so you can have 6 sides, make sure they fit on the 3mm plywood sheet, set power and speed (p= 50 s= 20) download the file, go to the laser cutter, select an origin point, check the time of printing, start priniting. 

Final box 1

Press fit box assembly on Fusion

Sketch of the left and right side

Sketch of the front and back side

Sketch of the top and bottom

Finale box 2