Box Design Guide

Design Guide for “What’s in the Box”


Round holes are easy to make

Square holes are hard to make because you have to drill a round hole first and then scroll saw and file the hole square

Square sides to boxes are easy

angles are more difficult

hexagons are easy to make

octagons are harder to make

it is possible to use angled joints to create an irregular shaped box such as a piano but this is difficult and time consuming



laser cut only 2 sides as a maximum

laser cutting on sides of box need to be done before assembly

use RGB mode

cut lines are all red in colour R255, G0, B0

vector engraving lines are all blue in colour R0, G0, B255

rastering(laser etching into the surface of material) is any shade of Black(white-grey-black)

it is possible to do gradients but only using grey scale



timber does not bend easily so round shapes and circles are difficult if not impossible to make

it is easy to cut solid timber

boxes with curves and other shapes

it is possible to slightly curve 3mm plywood in one direction

it is possible to cut curves into solid wood but it needs to fit in the scroll saw


nail and glue all joints

nails should be 2 to 2.5 times the thickness of the material that you are joining (for example if you are gluing and nailing 3mm ply to the base of your box you should be using 15 mm nails because that is the smallest nails we have, if you are joining the 12 mm sides of your box you should be using 25 or 30mm nails)


rebate joints are stronger than butt joints and make it easer to create square joints





Hoop Pine- native Australian pine and softwood

radiata pine

tasmainian oak/ victorian ash hardwood










pacific maple or maranti native Australian plantation hardwood











tasmainian oak/ victorian ash


ply wood

comes in a variety of sizes and colours you should be using 3-4 mm ply of the same colour of your box for the base and possibly the lid depending on the design.





tung oil and citrus terpine





25 lessons to finish project


week 1

1 lessons to complete research and PMI evaluations

1 lesson to complete  a rewriting of brief and mood board on “who you are”

3 lessons to complete 3 coloured concept sketches


week 2

1 lesson complete a PMI on your concept sketches

3 lessons to complete technical drawing




All students will be given the start of week 4 to finish their design work or they will be given a standard design by their teacher to complete for their practical assessment.


5-7 lessons of demonstrations by your teacher spread out across the duration of the project


1 lesson sawing and sanding wood square and to size

1 lesson to assemble a box

1 lesson attaching a base

1 lesson cutting rebates

3 lessons to apply a finish


Waiting for Mr Morrison can take a long time at different parts of the project times can be from 5min to 3 lessons


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