Star 3D Lasercut Box

This project follows how to create a Lasercut 3D Star box. This box was inspired by paper cut-out star lamps and the main intention of this project was to find a structure for a star-shaped box that could later have patterns cut out for light patterns to be emitted. The examples above depict the inspiration and the later vision of combining a box lantern and star shape in later iterations of the project.

This project used a Epilog Fusion Maker 36 Laser Cutter, cardstock, Fusion 360 for Designing and certain supplies like a pushpin, ruler and tape for construction.

To start with the design of this box, I took a look at a star and the set-up of a cube. I had difficulties deciding how to go about how to build out the sides of the star in order to shape it into a box. As seen in the second image, my initial thought was to build out the sides of the box with the inner corners of the star touching and then have a 'lid' star top. However the angles for this path were tricky to figure out. After help from my Professor, I was able to find a wrapping technique where each side will wrap around the star and the top and bottom stars were connected to one side square, as seen by the sketch labeled 'final'.

After physical sketching, I created a sketch on Fusion 360 utilizing certain tools such as the rectangular pattern tool and sketch dimension to ensure each line and angle was the same. Above are also the final parameters I set for each line. The main stars were all 0.9 inches on the sides with 36 degree angles in between each point. Additionally, the rectangles were 0.9 in width and 2 in height. The height was based on the amount of space in between the stars I wanted and is flexible for future projects. The sketch dimension tool was especially helpful as I had difficulties ensuring the equality of each line for the stars previous to learning about the tool. Additionally, the repetitive rectangles were easy to create with the rectangular pattern tool as each rectangle could be stamped instead of individually created with lines.

The time then came to figure out how I would put together the finished box. The wrapping squares would have to attach to each side of the stars. I decided that tabs would be the best for this part, however interlocking stars would make the star ends of the box to not sit flat on a table. Therefore, glue tabs would be the best past. To create these tabs I created arrows on the sides of each square however had a bit of trouble finding what lengths would work the best as it would have to fit inside the triangles of the star. I used parameters and the sketch dimension tool to ensure all lengths were the same. I then had to download the lasercutting tool for exporting this file and saved it to upload to illustrator. I intended to add score lines on the finished sketch in Adobe Illustrator in order for an engraved line to be printed for folding however I ended up scoring the lines by hand after to save time. In the future, I am looking to add score lines and additionally cut patterns into the sides of the box to create a lantern light look as seen in my reference above.

The sketch was printed perfectly into the red cardstock chosen after exporting through Adobe Illustrator. Once taken out of the framed paper, I used a pushpin and ruler to score each line for folding and then folded the sides around the stars and placing the tabs inside the star. I came to an issue with the glue I used for the tabs as it was not drying fast enough and ended up not sticking to the tops, therefore I used tape to fully close the box. In the future I would make sure to use a stronger glue or weight down the triangles more to create a more seamless, clean look without the tape.

And now the Star box is complete! Overall, I was very happy with the shape of the box and how each side fit perfectly and all the angles aligned. I would improve how the tabs worked in the design as due to the tape being used it made a messier look of the box and additionally didn't utilize the tabs and therefore added more work than needed to the process. I would look to find a way to make interlocking tabs work while keeping the tops of the box flat. Additionally, I will experiment with adding patterns to the sides of the boxes as seen in the reference picture of the star lantern. Also, due to the paper used the size of the box was limited to fit the 11in cardstock paper as the wrapping design of the box sides were very long. Therefore, experimenting with a different design could allow for less material waste and a bigger sized box. During the process, the most tedious part was creating each shape to ensure the lines were all the same, however once the tools above were figured out it streamlined the process a lot better and will make it easier to design in the future.

After reading Structural Packaging: Design Your Own Boxes and 3D Forms by Paul Jackson, I can revise the process I used to create my project. In Chapter 2, How to Design the Perfect Net, Jackson describes how it is very useful to, after sketching, physically put together your project as a box with paper and label each piece/side with a number to see how the shape fits together and which sides are touching. This process would’ve been very helpful and a tool I’ll utilize in the future after initial 2D sketching. Additionally, the process used to add the tabs in the box examples were very helpful in revising the design I used for the tabs as I failed to utilize the tabs I created in the end. After reviewing the tabs that Jackson listed, I believe the glue tabs in my design would be the most appealing look wise; however, to add a lid, the click lock would give a very clean look on the sides of the star lid.