I decided to take on the challenge of creating an affordable, collapsible light box for people who may be short on space as well as cash. The problem I found with many of the affordable foam core light boxes is that every time you want to take it down you risk having the tape rip the walls apart. That in combination with the potentially frustrating assembly as one fumbles with the foam core like a house of cards lead me to the idea of a dove-tail like joint for the box.
This light box design cost about $4 for the foam core and another $1 for the poster board that I use to create a seamless background. It's quick and easy to assemble, tear down, and store away. I still need to find brighter lighting, I used two dim desk lamps to test, but it definitely has potential!
Step 2: Cut into 20"X20" panels
First I cut the foam core into 20"X20" panels. I then labeled each panel according to it's location on the box to keep myself from getting confused.
After I labeled my 4 sides I measured a 1" thick margin where each joint connected. Then I laid out the panels according to where they connected to the 'back' panel. Imagine the sides and top folding up at each joint and you can visualize how the box will connect.
Step 3: Label panels and draw tabs
With the joints touching I measured out 3" notches and drew my line across both panels to ensure that everything would fit together nicely. For someone who is less than precise when it comes to measuring, this is a great technique to ensure a good fit. I then shaded in the notches that I wanted to cut out with my exacto knife. I did this to keep from cutting out the wrong notch accidentally.
Step 4: Check to make sure shaded tabs line up with non shaded
By tilting your panel up you can see where the notches fit into each other. The white ones, or tabs will fit into the shaded ones, the ones I cut out.