Challenge 5: Laser-Cut Frame & Build Log

⏱️ ~4 hrs

From screen to sheet. Translate your digital design into precise, real parts—and prove you can assemble a clean, square frame.

Overview

Your task: Laser cut all the applicable pieces to your puzzle box - which is most likely the six walls - and show its construction process from planning to assembly. This challenge focuses on identifying which parts of your puzzle box are suitable for laser cutting, preparing files in the correct format, and documenting the entire build process.

Obtain Inkscape at inkscape.org. Keep your work aligned with the requirements. Find locations to laser cut with this guide.

What to Do (8 Steps)

Identify Laser-Cuttable Parts

Select flat panels, frames, and engravable surfaces suitable for 2D cutting.

Create Cut Files in Inkscape

Size parts to match your design; ensure units are consistent.
Apply line conventions (e.g., red=cuts, black=engraves), appropriate stroke weights.
Save/export as vector .svg for compatibility.

Compile a Parts List (PDF)

For each part: name/ID, dimensions, material & thickness, function.

Choose a Cutting Service

Locate a shop or makerspace to run your job (guide).

Laser Cut Your Parts

Submit finalized SVGs, run the cut, and verify dimensions against your plan.

Assemble the Frame

Build the box using only the laser-cut parts (no 3D printed parts for this challenge).

Document the Process

Capture before/after photos showing loose pieces and final assembly.

Quality Check

Confirm fit, squareness, and that edges/engraves match the plan.

What to Submit

A publicly shared Google folder (so anyone can view) containing:

Parts list PDF (with descriptions of each part)
Exported vector file(s) (.svg) created in Inkscape
Before & after photos of the construction of the box using only laser-cut materials

Pro Tips

Add dogbone/teardrop reliefs for tight inside corners if parts slot together.
Account for kerf in tab/slot fits; consider a small press-fit test coupon first.
Keep strokes hairline for cuts; avoid stray fills that could raster unexpectedly.

✓

Why do this?

Manufacturing literacy — learn file prep conventions (stroke colors/weights) and vector standards for laser cutters.
Tolerance awareness — cutting real parts reveals kerf, fit, and material behavior you can’t see in CAD.
Documentation discipline — a clear parts list and build log mirrors real shop practice.
Progress to production — this is your bridge from design to reliable fabrication aligned with the requirements.

Scoring (Total: 125 pts)

Parts Documentation

PDF parts list is clear, complete, and accurate.

25 pts

Vector File Quality

SVGs are correctly scaled, labeled, and use proper line conventions.

35 pts

Fabrication Quality

Laser-cut parts are accurate, clean, and usable for assembly.

30 pts

Assembly & Construction

Final frame is correctly assembled and well-documented with photos.

20 pts

Challenge 5: Manufacturing Mastery

Challenge 5: Laser-Cut Frame & Build Log

Overview

What to Do (8 Steps)

Identify Laser-Cuttable Parts

Create Cut Files in Inkscape

Compile a Parts List (PDF)

Choose a Cutting Service

Laser Cut Your Parts

Assemble the Frame

Document the Process

Quality Check

What to Submit

Pro Tips

Why do this?

Scoring (Total: 125 pts)

Create a New Submission

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ManufacturingChallenge 5: Manufacturing MasterySubmission240minEliteDescription

Challenge 5: Manufacturing Mastery

Overview

What to Do (8 Steps)

Identify Laser-Cuttable Parts

Create Cut Files in Inkscape

Compile a Parts List (PDF)

Choose a Cutting Service

Laser Cut Your Parts

Assemble the Frame

Document the Process

Quality Check

What to Submit

Pro Tips

Why do this?

Scoring (Total: 125 pts)

Create a New Submission