Week 2: Modularity (Press-Fit Box)

My objective was to create a kit of laser-cut press-fit parts, ensuring a precise and secure fit between the parts. I designed a press-fit box using Fusion 360. I iterated on the design, adjusting tolerances to ensure the parts fit together securely. After printing a test set and conducting fit tests, I finalized the design and printed the components for the press-fit box.

• Fusion 360 (or any CAD software)
• Laser cutter
• Cardboard (for initial testing)
• Wood (for the final version)

1. Open Fusion 360 (or your preferred CAD software) and create a new project.
2. Begin designing the box, considering its dimensions and overall structure. Take into account the desired thickness of the material and the joint tolerances.
3. Create the press-fit joints by designing slots and tabs that will interlock securely.
4. Once you are satisfied with the design, export the file as a dxf using the laser cutter extension for fusion which allows for tolerance adjustment.
5. Experiment with different tolerances. I started with 0.15mm and decided on 0.17mm for a tighter fit. Adjust the dimensions of the slots and tabs accordingly to achieve the desired fit.

1. Prepare the laser cutter by loading the cardboard and ensuring proper alignment.
2. Import the design file into the laser cutter software and configure the settings for cardboard cutting.
3. After leveling the bed, start the laser to cut out the components of the press-fit box.
4. Assemble the cardboard prototype, paying close attention to the fit of the joints. Evaluate the tolerances and note any adjustments needed.

1. Now that you have refined the design, it's time to create the final version using wood.
2. Prepare the laser cutter for wood cutting and load the appropriate material.
3. Import the final design file and configure the laser cutter settings accordingly.
4. Laser cut out the components from the wood.
5. Sand any rough edges and apply any desired finish to enhance the aesthetic appeal of the box.
6. Assemble the wooden press-fit box, observing the carefully adjusted tolerances and experiencing the satisfaction of a well-fitted final product.