Make a Parametric Cardboard Shelf

In this project, you’ll learn how to design and build a stylish shelf using cardboard and laser cutting! This shelf is parametric, which means it can be customized easily by changing the design in Fusion 360. It’s perfect for displaying 3D printed objects or small collectibles.

Supplies

3D Design Software – Autodesk Fusion 360 (or similar)

Cardboard sheets – 5mm thick

Laser cutter

✂️ Craft knife or cutter

Glue – white glue or hot glue works

Drill machine and drill bits

Screws and washers – for mounting

Screwdrivers

Step 1: Plan Your Shelf

Start by sketching out a few shelf ideas. Choose your favorite design before moving to Fusion 360.

Step 2: Design in Fusion 360

Open Fusion 360 and start modeling your shelf. We’ll build it using surface modeling tools.

Step 3: Make the Basic Shelf Shape

Use Loft to connect three different sketches and create a 3D surface. Then use the Patch tool to turn it into a solid body.

Step 4: Create Finger Joints

On the back of the model create a new sketch to draw the curve using a spline tool so you can get fingers for finger joint afterwards. Make sure the spacing matches twice the thickness of your cardboard.

Step 5: Build the Back Panel

Extrude the back of the shelf. Use two layers of cardboard to make it strong.

Step 6: Plan Cross Sections

At one end of the shelf, sketch a rectangle and turn it into a surface. Use the Rectangular Pattern tool to copy this shape across the shelf, spaced at 2x the cardboard thickness.

Step 7: Slice the Shelf

Use the Split tool to cut your main shelf body into many slices (cross-sections).

Step 8: Hide Every Other Slice

Hide alternate slices so we can work with fewer shapes at once.

Step 9: Create Flat Sketches for Cutting

On each visible slice, sketch and project the edge so you can later cut it from cardboard. Then extrude these sketches into flat pieces.

Step 10: Add Slots to the Back

Use the Combine tool to make slots in the back wall for each cross-section to fit into.

Step 11: Add a Third Back Layer

Make another layer for the back—this one will hold special connectors (called butterfly joints).

Step 12: Add Butterfly Joints

Split the back into four parts and design butterfly joints to hold the back together like puzzle pieces.

Step 13: Export Your Cutting Files

Export all your sketches as DXF files for laser cutting.

Step 14: Prepare Files for Cutting

Open the DXF files in Illustrator (or similar software). Add numbers to the parts and arrange them to use as little cardboard as possible.

Step 15: Laser Cut All the Pieces

Import the files into your laser cutter software and cut out all the pieces.

Step 16: Double Up the Layers

You’ll need two layers for each cross-section and back panel. Stack and glue them together.

Step 17: Assemble the Back Panel

Use the butterfly joints to connect the four back pieces into one strong back wall.

Step 18: Assemble the Shelf

Slot all the cross-sections into the back panel. Use glue to hold everything together.

Step 19: Let It Dry

Leave your shelf to dry for at least one day.

Step 20: Mount on the Wall

Drill 4 holes through the back, then use screws and washers to mount your new cardboard shelf on the wall!