I'm slowly getting better at using Inkscape to create laser cut boxes for electronic projects. I've never been a big CAD user but did spend a few weekends learning Sketchup to layout my custom workshop/shed. But for making Laser Cut boxes, it became clear that I had to learn either Corel Draw or Inkscape. And since Inkscape is open source and free, I chose Inkscape to start.

It was not intuitive for me to just start using it. I had to watch a few Youtube videos just to get started. But before long I had the basics down. At first I used it to add features to boxes I created with Makercase but that software kept crashing on my old Mac so I just decided to draw on my own. A friend recommended a tabbed box creator plugin for Inkscape so I tried it out and what a great tip that was.

The plugin is called Boxmaker and you can easily install it by copying the files to the ...\Inkscape\share\extensions folder of your Inkscape install. That's it. Start up Inkscape and its ready to use. This is a great way to get started with a new... 

Makercase (makercase.com) has released an updated version that allows you to adjust the tab size for Finger and T-Slot joints. It's limited to 1/2 the smallest side of your box but this is a great addition to this handy application.

The adjustment shows up as a slide under the box picture when you select Finger or T-Slot. Below are two examples of a box adjusted for different tab sizes.

I just completed my first box with the MakerCase.com online tool for designing laser cut boxes. The software is easy to use and getting better all the time. I decided to create a clear acrylic box for my BasicBoard design that has been sitting around on my bench for a while now.

I made a 4.1" x 2.8" x 1.25" box with holes in the top and bottom that line up with holes in the board. Then I added rectangular holes in the sides so I could easily access the switches, expansion ports, programming header and on/off switch. 

The edges have interlocking fingers to make the design easier to build and make a stronger box. The idea was to glue the sides together then hold top and bottom together with standoffs that will also hold the BasicBoard inside.

When the design was done, I had MakerCase generate the .svg file. This file was then taken to my local engraver (The Village Engravers in Milford, Michigan) who has an Epilog Laser. He typically just engraves trophies and plaques to pay the bills but he likes to help creators by also cutting out designs. It only took about 10 minutes to get two boxes cut out and give me two sets of the pieces shown below.

A little dab of superglue on the middle tab of the short sides was all I needed to make the sides bond together. I used some jack screws to mount the BasicBoard and then put all the pieces together as seen below.

I didn't have the correct length standoffs to place on top of the jack screws that will hold the BasicBoard tightly in place and also create the mounting screws for the top so I ordered some from Jameco.com. I hope to have them in a few days.

I also wanted text engraved into the top and bottom and had that in the final design but somehow the file would not load at the engraver. Fortunately I also had the non-engraved text version on the flash drive that loaded just fine so that was laser cut.

My head is spinning with ideas of what I can produce with this design software. And I'm already thinking of ways to get around the rectangular box design. If I put a hole in the center of one of the discarded cutout pieces, they can be sized to become robot wheels. Or make a large square box with large circle cutouts and then the large circle cutouts become the levels of a round robot base. And all this without ever having to learn a CAD/graphics program like inkscape or corel. How great is that?

I want to add either a 3D printer and/or desktop CNC machine to my lab but I still haven't decided which one to get first. I'm not great with CAD software so its a learning curve either way. 

I've been trying to find the best software options to get started and they are both getting easier. But I don't think you can beat this new software called MakerCase by Jon Hollander. You just put in the dimensions and it creates the box for you. Then you can add round or square holes. On top of that you can add text to be etched on top of the panels. When your done it outputs a .svg file for direct import into a Laser Cutter. 

I'm just getting started with this software to see how well it works and I have a place near my workshop that does laser cutting for a low price, so this may be my first step towards making my own boxes for my electronic projects.