# Laser Cut Cryptex - Puzzle Box

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## Introduction: Laser Cut Cryptex - Puzzle Box

This project has been made on a laser cutter that I used at FabLab Innovation (http://www.fablabinnovation.dk/)

Ever since seeing the movie - the Da Vinci Code - I have been fascinated with the cryptex, a small scale combination vault, that can only be unlocked by entering the right word on the scroll, allowing the user to pull out a tube which contains some sort of secret.

I decided to construct my own cryptex using laser cut parts, by that I mean only laser cut parts. In this project I developed 3 versions, an initial prototype to see if I could construct the basic mechanics in the cryptex, a second version that had a more aesthetically pleasing design, and the third and final version that had some improvements, that I came up with on my own. The cryptex has a total of 343 parts that are glued together. In this instructable I will describe the process and thoughts behind the different features in the cryptex and how I build it. I will also include the files for building one yourself.

If you like this instructable, please consider voting for it in the Full Spectrum Laser contest by clicking vote in the upper right corner of this instructable, I would really appreciate it. Thank you in advance.

## Step 1: The Final Version

Before going through the process of creating this cryptex. I will show the final version.

The final version has the ability to lock in secrets using 10 discs with 26 letters on each disc, that is a total of 26^10 different possibilities or 141167095653376 different possibilities, of course, in practice this is not true, because a cryptex will normally contain a keyword that makes sense, eg. in the Da Vinci Code the keyword is "apple", so a lot of possibilities can be ruled out, eg. words like "ehuakebnps" which is just a sequence of random letters, this can of course also be the keyword, but it is highly unlikely considering that a cryptex is normally unlocked through some kind of riddle.

In the first two versions, I had some issues with positioning the letters 100% correctly, so it could be difficult to unlock the cryptex, so in the final version I added a "click" function, where the disc would be turned 1/26 of a turn and click into position, it could also only be turned clockwise (when looking from the right hand side), this made it far easier to position the letters, and also gave a nice rattle sound similar to the one that can be found in a ratchet, while the mechanism I used in this cryptex, is almost identical to the mechanism found in a ratchet. I also raised the disc with the letters, making turning the disc a fair bit easier, since I expected some resistance from the clicking mechanism.

I can of course not claim the mechanical design in the cryptex as my own idea, since it is exactly how a standard combination bicycle lock works, but the idea of inserting a spring loaded gear to add the clicking effect, I believe is original. It might be that somebody else got the same idea, but I came to this idea independently.

The whole cryptex is made entirely out of 3 mm. MDF, and uses a total of 343 parts, though 260 of those parts where the individual letters, because each letter had to be inserted so the cryptex could be made to open up with a chosen keyword. Assembling one takes up to a few hours. The whole thing is assembled using only PVA glue, and afterwards I gave it some WD40 to make it turn smoothly, though in hindsight using grease would have been better since MDF has a tendency to suck up liquid and expand (though I have had no issues with that so far), and not everybody likes the smell of WD40, I do not mind it though.

## Step 2: Basic Mechanics of a Cryptex

A cryptex might seem like an intriquate machine, and in some ways it is, but most of it is the same mechanism repeating itself in a row. Inside the cryptex, there is a long recess that is made out of a series of notches, every other notch (the discs without the letters) are locked into place, the notches on the discs with the letters can rotate though. The tube that sits in the cryptex has some keys or teeth. These keys will sit in the notches that are locked into place, and to pull the tube out, the notches must align to make one long recess where the keys can slide through. If it is a bit confusing the video will explain it a bit better. So as you can see the cryptex is actually fairly simple. Since the end pieces in the cryptex, also are locked into position the can be used to keep the whole thing together. The bars on the outside of the cryptex are the ones that keep the whole construction together, I later moved them to the inside of the cryptex to make it look nicer and so they could not be removed by force and then allow the cryptex to be opened without the keyword.

## Step 3: Clicking Mechanism

As I wrote in the beginning of the instructables I had some problems with having to very precisely align the letters to open the cryptex and that bothered me, so I decided that I needed some kind of clicking mechanism so the letters would align themselves. I did that by adding a inward facing gear between the static and dynamic rings(the rings that can not turn and the ones that can, ie. the rings with and without the lettes) and then I also had a ring with a "spring" that would be able to bend down when the gear is turned in one direction but will lock the gear when turned in another direction, this gives it the clicking effect and also makes it more precise. The recess on the inside is made for 3mm. keys but I added 0.5 mm. on either side, to give it some tolerance. It also gives the cryptex a really nice tactile feeling when using it, and the sound is also very nice. I cut out some of the gear tooths to make a round surface where the inner part with the spring would turn, to make sure that the construction is concentric.

In hindsight it would have been better if the cryptex could be turned both ways.

## Step 4: Design Features

On top of wanting to have a functioning cryptex, I also wanted one to have on my shelf at home, as a kind of conversation piece. I liked the look from the davince code, where the cryptex looks like a rolled up codex or scroll. So in the final design, I made the end pieces have a bigger diameter than the middle part, I also wanted to have some kind of indicator where the word has to be aligned, so I kept one of the crossbars from the first version, to have it as a display. As a last thing I also made the radius of the letters discs 1 mm larger, to get a better grip, but that also added a nice design feature that made the disc have kind og a checker pattern.

## Step 5: Building the Cryptex

The cryptex is made out of laminated sheets of 3 mm. MDF, it in some ways mimicks the same way a 3D-printer works. The parts are laminated using normal fast setting PVA glue, the same stuff one would get in a craft store.

## Step 6: Dynamic Disc

The dynamic discs are made out of 3 parts. The gear for the clicking mechanism, the middle part and the disc with the spring mechanism. Afterwards the letters are added. If the disc has to spell out the letter C, the letter C should be in the recess outside the notch where the key goes through, afterwards come D, E, F etc. in the counter clockwise direction, so when the disc is turned clockwise the next letter shown is the next in the alphabet. Then it goes all the way to Z and then from A to the start letter, in this case C. To make sure that the gear align correctly the spring disc is inserted and aligned so the notches for the key align.

## Step 7: Static Disc

The static disc is made the same way that the dynamic disc is made, but without the letters. As simple as that.

## Step 8: Inner Tube

Unfortunately I have no pictures of assemblying the inner tube, and there is not really that much to it, so hopefully the picture of the final part will do.

## Step 9: Final Assembly

This is the most crucial step, after gluing these parts together, there is no going back. The most important thing to do, is to make sure that the discs are in the right order and sequence. The disc has to alternate between static and dynamic, and the letters has to be in the right order. The individual discs are made so they have an inner part on one side and an outer part on the other, this is the case for all the discs, when they are stacked the inner and outer parts will make the discs turn concentric and lock together so they can not be shifted. On the static discs there are finger joints on the inside, that will be mounted on 4 connectors, that also holds the end pieces together and lock all the discs in. The discs should be stacked so the recess aligns, then the assembly bars get some glue and are added on the inside, this is a difficult step because you do not want glue all over the inside of the cryptex, or it will get stuck.

## Step 10: Conclusion

After making 3 versions, I ended up with a working, somewhat good looking cryptex. With the added bonus of the click effect. Though I would have liked to be able to turn the wheel in both directions, and there is a bit of twist in the structure, but that is due to the material and because I used glue instead of eg. screws.

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## 109 Discussions

I need dxf file. Cause file you are provided above is not working with my software. Im using RD works. please provide me proper dxf file. Thanks in advance.

Thanks for your clicking mechanism, it inspired me. Made with one Chinese laser machine and printed with Roland LEF2-200. A few photos of my project

Hello!

Do you sell this cryptex anywhere?

I currently do not sell it, but I might be able to do so in the beginning of next year. I have purchased a laser cutter to have at my home. I will notify you when I get it, if you are still interested in buying one. I also have to figure out how much it will cost, either as a kit or a final product. The finished product might be quite costly since it takes a long time to assemble it.

Any chance you are selling the kits now?

Got your password ;-) anyway, nice work. Only two things I'm tried to figure out are:
1/ how to add the possibility to change password. I mean some trick with one more inner wheel positioned directly behind the most outer one, which could be rotated in "opened" position. (take all the wheels out, change password and take wheels back in).
2/ how to make "metal" version - the "spring" probably will not work, so there's need of any real spring with ball or anything simmilar closed in tight chamber and fit into small holes instead of the gear.

Hi. I thought I was almost finished with making one - my first (and way too ambitious, I know) laser-cut-project. I stacked the rings on the inner tube, to see if it worked, but the dials were so hard to twist that I snapped the inner tube in half. I've made it, as specified, in 3 mm. MDF, and the dials CAN turn (I found out earlier, that the direction of the spring/gears has to alternate (something that would have been nice to be mentioned in the instructions, btw ;0) )), it just take some force to do it - at least the first round or so.

Any pointers? I've loved the project, and would hate to abandon it, but it just seems to be a bit much strain to expect from something that's pretty much card board. And it's supposed to be used by a lot of different people, so I can't just expect people to handle with extreme care.

The main picture you show of the dynamic disc, seems to show a ring that is not part of the current cut files.It is the ring on the right side of the assembled disc. It is solid with only a notch. Was that from a previous version?

Hi,

I was hoping you could help me! I'm up to the assembly section but am very confused about about how to stack the discs so that only the dynamic ring turns. I'm finding that the dynamic ring is stuck and won't turn when it is lodged between two static disks and mounted to a connecter.

I haven't glued it on yet because I'm not sure what is happening with it. Am I correct in saying that the static discs shouldn't turn at all once assembled? And that the static and dynamic discs don't need to be glued together?

I'll add some images of my discs so far.

Well, thank you very much for the project and I'm excited to do so. I cut the pieces but I have many and many doubts that only appeared after I have them as a puzzle in my hands.
How many pieces are each? What are the exact design that should be used?
There is no information on how to start, how I make the blood of static and dynamic parts, and also the beginning and the end.
Honestly I'm very lost and I feel a little bit embarrassed to come here and write all this (plus everything using google translator), it's not critical, it's an otmio project! But I'm too young and I'm having too much trouble.
How could you help me?
Thank you.
Congratulations on cryptex and the initiative to bring it to the public.

hello, I've been looking for something like this and am anxious to build it. However, I'm having problems with the files. The only one I can open is the adobe illustrator file. The others give me a file corruption error. Do you have links to the files elsewhere? Thank you.

Greetings, you really need to improve assembly guide. Right in the end i noticed i can't rotate the parts, the direction of the teeth are wrong. It's hard to understand how to assemble.

Ideally was to remake the instructables step by step and show us good methods to start assembly.

Also found few parts not with the right size.

It looks like you have different versions in the photos.

Please reorganize, it's a really cool project

Hello

The inner piece worked up nicely, and i enjoyed this project. Do you have dynamic and static disc assembly instructions? would appreciate them.

Thanks

Hello,

I'm sorry. But Am I missing something? I am having some issues with dynamic and static discs. Do you have a blow up diagram to be able to understand the exact assembly? If you can, would be appreciated if you can post or send to my e-mail. amernajm@hotmail.com

wax is the better solution, ordinary candle wax ...

Thanks for the tip! I'll use it next time.

Hello friend, I like your work. It is awesome. I tried to make my own model but I've failed.
Thanks for share your work with all of us!

I have a question: Can I change the combination of lock?

Changing the combination is fairly simple. In the disc where the letters go there is a notch on the inside where the key slides in. Put the letter you want in your combination in the indent on the outside that sits at the same angle as the notch on the inside. The next letter should be the next in the alphabet, so if you letter on the disc you're working on is g, then h should be the next and so forth. When you reach z add the "a" letter and work your way up to the letter you added first. Do this for all the disc.

This is an amazing project. I loved it and chose it to be my first project. However, I am very new to laser cutter and design programs. I could not manage to scale it for 5mm wood. Is there anyway you can upload this project scaled for 5mm wood? (cdr or dxf extension would be perect). I appreciate it and many thanks in advance.