This flat-pack design was inspired by the SketchChair software I saw recently.
Step 1: Design
The DXF of the parts is located on my website.
Step 2: CAM Programming
I exported the the drawing of the pieces via DXF to my Vectric Aspire CAM program. Here I duplicated the parts to what I needed and used the nesting feature to fill the cardboard size I had. Normally I would restrain the amount of rotation allowed to keep a consistent grain direction, but this time I let it rotate any any angle (screen says 45deg, but I actually used 5deg). I wanted the finished product to look sort of cattywampus.
Step 3: Fabrication
The material I used was a single, used, medium USPS shipping box. This is very light cardboard at 1/16″ thick. I cut it using my open source laser cutter. I ran it at full power at about 40 ipm and a little assist air to stop the fire. I probably could have run faster, but It was my first time with this material.