The key to these boxes is the narrow to non-existent kerf left by a laser cutter that makes interference fits with wood a reality.Martins design leverages the slot and tab connection were used to seeing in laser-cut boxes, but adds a living flex-hinge to curve each piece of plywood into a U-shape.
The two pieces are then nested together like those old aluminum hobby enclosures from Radio Shack. His GitHub has OpenSCAD scripts to parametrically create two different styles of two-piece boxes so you can scale it up or (somewhat) down according to your needs. Theres also a more traditional three-piece box, and any of them might be a great choice for a control panel or small Arduino enclosure. The technique is not as interesting or useful as you might think. You cant make, for instance, a wooden cover for a 1 thick book (or even a 2 book) with a living hinge because you cant make a hinge that bends that far that quickly. Of course this puts more stress on adjacent links, so this leads to a cascade failure. Covering the hinge with adhesive-backed leather, for instance would probably work. ![]() ![]() I think most of that Baltic birch uses interior-grade glue, especially the thin stuff like 5mm (14).
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