3D Modeling and Fabrication — Laser Cut Project

Step 1: Brainstorming

I had never worked with a laser cutter before, so this was an exciting first project. I was familiar with some laser-cut projects, like jigsaw puzzles and dice towers, but I had no idea what went into the process (or how easy it was to turn a concept into a finished piece!)

I was particularly inspired by box cuts, living hinges, and layered acrylic patterns.

My first idea was a candle holder using living hinges to form the outside, where light would shine through the hinges. It turns out that there is some complicated math (or trial and error) needed to get the hinges right without it breaking. I would come back to the candle holder idea later on though…

My second idea was a layered acrylic portrait of a thunderstorm. I wanted to experiment with using painted wood and yellow/pink/purple acrylic sheets to make dark clouds, possibly using vinyl cuts or paint for lightning. Though I love this idea, it’s a bit ambitious for a first foray into laser cutting. I’ll hopefully revisit this idea some day.

My third idea was a dice tower. I am a passionate fan of tabletop role-playing games like Dungeons & Dragons, and wanted to craft something that would integrate with game sessions. I had seen elaborate designs for dice towers (like the ones above) and wanted to make something like that. I realized that level of detail was difficult for a first attempt, but I didn’t want to start with a plain box, so I researched some arch patterns that I could use to add some flair to the design.

Step 2: File Work

I ultimately decided to go forward with the dice tower. It would be approachable as a beginner and could be easily iterated on. Also, there is a large community of tabletop hobbyists that had documentation of their own experiences making dice towers.

I started by using an online template called makeabox.io to form the dimensions of the tower. From there, I modified the base and sides to extend past the bottom, and added slots for the slides inside the tower. When attempting to cut the prototype, I was thankfully assisted by a professor who helped me modify my design by accounting for laser cut width and arrangement on the cutting bed to make the best use of space.

The large gap in the top-left corner was to account for a previously made cut in the wood I was using.

Step 3: Prototype

With the first attempt cut, I was able to learn quite a bit about the process involved and what kinds of modifications I would need to complete the final dice tower. I held the structure together with tape, and the front tray didn’t have a back wall, so dice would just roll out of the box. Overall, I was very pleased with the structure — I just had to make the design more functional and less boring.

I researched arch patterns that I could use for cuts and engravings along the outside. I originally considered adding windows, but I was afraid of getting the dimensions wrong and having the dice fall out. Since I was also on a bit of a time crunch, I went ahead with just laser cuts and basic engravings. I also modified some of the teeth used in holding the box together to make parapets, to give the design a little more appeal.

Step 4: Final Assembly

I was very happy with how this project came out. It works exactly how I wanted it to, and even works with different kinds of dice! I would love to expand on this idea in the future with more elaborate patterns, and maybe even windows. I would also like to experiment with acrylic, and having more elaborate slides that you could see through the transparent material.

Here it is in action!