Week 2 Paper Folds

For this project, I designed and fabricated a 3D paper form from cardstock using a parametric 2D net in Fusion 360. The goal was to connect digital design with hands-on fabrication by transforming a flat net into a precise, foldable structure.

I began by sketching my idea on paper. My goal was to create a box, since I wanted to start off with the basics.

I annotated the shared edges and added dimensions to understand how the flat net would transform into a closed object. This helped me plan where to place tabs and fold lines.

Next, I modeled the net in Fusion 360. All sides were fully parameterized, which meant I could easily adjust dimensions without breaking constraints.

I added small tabs along the edges for assembly and designed fold lines that would later be engraved during laser cutting. These engraved folds make the creases cleaner and more accurate.

Once the design was complete, I exported it as an SVG and used the Makerspace laser cutter with cardstock cut + engrave settings.

I folded the net along the engraved lines and used tape/glue inside the form so the outside stayed neat.

The final result is the box that is fully closed, cleanly folded, and structurally sound. I was happy with how professional the engraved fold lines looked.

If I were to improve it, I would experiment with more complex geometry to make the form more durable or visually interesting.

Reading Paul Jackson’s Structural Packaging had a strong influence on my process. The section “How to Design the Perfect Net” made me focus on how edges and folds relate to each other to ensure the design could actually close cleanly. “Common Closures” helped me think about the role of tabs, not just as functional but also as part of the neatness of the outcome. Skimming “Creating with the System” encouraged me to try a less primitive shape and think of nets as flexible systems rather than static patterns.

Overall, the reading pushed me to see packaging design as a balance between geometry, structure, and aesthetics. This perspective shaped how I approached the sketch, digital design, and final assembly.