Box Complete March 29

After cutting out sketch 3 as a 1'' x 1'' box I realized that screwing on the screws takes patients and skill to properly make the screw go into the designated hole. The dimensions of the current holes as .1'' which are just about right.

Sketch 3 requires 4 screws. The top and left sides are 1/4'' shorter in length since the width of the lid would add to the length of the side (sides need to be 2'').

The knowledge I gained from sketch 3 was that I need to make my design easier to assemble (screws are a pain). Thus I revised sketch 3 and decided to add tabs on the sides. I had to resize the dimensions of the holes for the tabs to lock in (the length of the holes must be equal to the width of the material).

Revised version of sketch 3 without screw holes. The tabs are longer than the width of the material because I want to see how well it will hold the sides together.

Cut out of revised version of Sketch 3

In this prototype there are 2 holes for the lid to connect and these sides are taller.

Tabs worked quite well.

 I tried to make the holes for the tabs as close as possible to the edges to reduce how far the sides with the tabs will have to bend. This meant that the sides will not connect at 90 degree angles (you would have to use a different method for attaching the sides at right angles) and small gaps between the sides will be unavoidable.

The last changes I made to my design were making the tabs the same length as the material and having one tab and hole for the lid. Making changes to the lid also made it necessary for there to be only one side shorter than the rest (the shorter side had to be across the side with the hole for the lid to slide in).

The final lesson I learned from cutting out my design in acrylic and wood was that material is important. Delrin allowed the living hinge to bend without breaking; acrylic and wood would break.

Here is my final box! I customized it with stars and a moon that is not visible in the picture. 1/8'' Delrin velocity: 0.7 power: 100%