I've been trying to develop a puzzle that requires a box with very, very specific dimensions. I couldn't find a ready-made box of the right size so I tried building it with laser-cut acrylic panels, but the box didn't have the right characteristics...and I lost access to the laser so I couldn't continue experimenting with it.
To build the box on the SD300 I designed a flat model with hinges that would reproduce the exact interior I needed when the wall panels were folded.
For stability I added a ridge along one edge that could engage tabs on the side walls.
When the panels are folded into the right shape there's a groove around the top rim of the box.
A separate plastic rim snaps into the groove, thereby completing the box.
The finished box matches the dimensions of my laser-cut prototype, but it adds the lid mechanism that was missing from the laser-cut model. Now I can build as many as I need.
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