Instructables
This instructable shows how I made a laser cut box with a curved lid to house a wireless sensor node.  I made it at Techshop SF.  The node measures temperature and relays its measurements to a central logger so that I can plot graphs from the data.  The box needs a port for the antenna, good air flow for the sensor and it needed to be attractive so it can sit on a shelf unnoticed.

I did all my laser cutting at TechShop San Francisco.  It was my first attempt and 2 of the 3 boxes that I made worked out but one broke when I tried to bend the lid into place.  I tried 3mm MDF, aromatic cedar "laser wood" from www.laserbits.com and birch "laser wood" from the same.  The MDF cut and bent perfectly; the cedar burned quite a lot in the cutting (more on that later); the birch cut well but it was too thick to bend.

[Update] I've now improved the design (pictured) and it works perfectly with birch as well as the other woods.  See the final step for the updated design files.

Materials:
  • ~3mm laser ply or MDF.
  • 6 x 10mm M2 screws and nuts.
  • 1 x wireless sensor node (mine is my own design but a friend of mine has written up a very similar one, from which mine is derived)
  • 1 x laser cutter, I used a 60W Epilog Helix.
The design files and code are available in my github.
 
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putyn1 month ago

Hello great project, but i have one question im interested in building something using living hinge, but im not really sure how to calculate the spacing or the length of the cut lines. Can you give me more details on how you calculated them or its trial and error ?

fasaxc (author)  putyn1 month ago
It was trial and error. I think I shared the plans on the ible though so you can start with that. I think the bands were about the same width as the material was thick. The top of the boxes is very flexible, you can bend it much tighter than the box requires.
streetart11 months ago
This is good! But i can't download the file.
jhall302 years ago
I've found that I can save Inkscape files as PDFs (on the Mac), or export PDFs from Illustrator, and then "print" them from Acrobat Reader (on a PC, of course, as Epilog's driver doesn't support Mac OS). Inkscape (and Draw Plus) rasterizes when printing, so it is only useful for raster engraving on Epilog laser cutters.

Regardless of TechShop SF's use of CorelDraw, you don't need to use it. Printing from Acrobat Reader works just fine, as the Epilog driver mimics a printer driver, and can be used from any program (it must print a vector image to cut).

I did have problems importing some file formats to CorelDraw, as it appears you have found. Since I primarily work on a Mac, I am happiest just using PDFs for the actual cutting. The same trick works with Inkscape on Windows.

Beautiful work, by the way, and great instruct able. Now I want to find some reason to make one of these (or I could just make something pretty).
fasaxc (author)  jhall302 years ago
Thanks for the tip. Just to be sure I understand, you are saying that the Inkscape->PDF->Acrobat reader->Print to Epilog path does not rasterize vector lines, so it should work for both vector and raster engraving? (But if you just print from Inkscape then it rasterizes before printing so that's no good.)
jhall30 fasaxc1 year ago
Correct. Printing directly from InkScape rasterizes the image, while exporting to a PDF file does not. Acrobat Reader will then send the properly vector image when printing.
tytower2 years ago
This is a novel way but not very structurally sound.
saw kerfs on the underside 2/3rds the way through 1/2 inch apart would look better and finish better plus some epoxy glue added later upside down to the kerfs would make it strong enough to stand on
fasaxc (author)  tytower2 years ago
I quite like the aesthetic of the living inge. It's more than strong enough for my purposes. The plywood is only 3mm thick and the whole box would fit on your palm; I don't think cutting a "traditional" kerf bend, as you describe, at that scale would be easy.
Rob3112 years ago
do you have an instructable about the wireless network?
fasaxc (author)  Rob3112 years ago
Not yet. It's on my todo list. It's largely based on the one described by a friend at http://mchr3k-arduino.blogspot.com/ (search for Wireless sensor node, I think it starts in Jan 2012).
laserline2 years ago
FWIW: I cut quite a bit of 3mm ply. I find poplar bends far more readily than birch.
Kewl project!
fasaxc (author)  laserline2 years ago
I've updated the design with narrower zigzags. Now it works perfectly with all the wood that I've tried.
fasaxc (author)  laserline2 years ago
Thanks for the tip. I think I have some poplar ply as well (looks just like the beech).
sabu.dawdy2 years ago
this is a very lovely instructable . this will look awesome in form of jewelry box =)
fasaxc (author)  sabu.dawdy2 years ago
Thanks. I'll upload the design files to my github soon so people can base their own designs on them.
you are welcome :)
Informative and stylish, love it.
fasaxc (author)  The Cartographer2 years ago
Thanks.
jo_mo2 years ago
Well done. Got to make one too. In my experience using any plywoods can be a problem with these type of "bendy" cuts. I'm open to any suggestions.

Keep on with Inkscape. It's the future!
fasaxc (author)  jo_mo2 years ago
Yep, it was definitely hit and miss. Need to get my hands on some thin sheets of real wood.
Lorddrake2 years ago
did you try steaming the top cover to make it more plyable before attempting to bend it?
fasaxc (author)  Lorddrake2 years ago
No, I haven't tried steam bending. I'd be a bit worried that this sort of ply (veneered MDF) might delaminate or swell if I exposed it to water. Any thoughts?
veneered MDF will more than likely delaminate if you try to steam it.

I thought this was made from one of the solid woods you listed at the begining ( that will teach me to skim and comment lol)
fasaxc (author)  Lorddrake2 years ago
Unfortunately not, I'd like to work with thin planks of wood instead but I'm not sure where to go to buy such things. I bought my "laser wood" from laserbits.com.
lyaxovvv2 years ago
cool
fasaxc (author)  lyaxovvv2 years ago
Thanks!