Overview:
In this lab, I learned how to construct a simple box made of foam core by first mastering the creation of corners (joint, lap, and larger radius) then developing a larger box.
Getting Started:
Before I began cutting the foam core, I familiarized myself with the tools and tips.
- The X-Acto knife is the most important tool for this lab and keeping it sharp is imperative.
- A metal straightedge is helpful for keeping sides straight and at 90 degree angles.
- A large and cut proof surface keeps the knife from dulling and simplifies the work.
- Adhesives like hot glue are important because they hold separate parts together (lap joints and folds)
- Proper cutting techniques
- use the whole blade instead of just the tip
- don't cut through foam core all at once
- Joining techniques include sharp, lap, and larger radius joints.
After understanding the basics, I began each corner the same way. I started out by using the metal straightedge and the X-Acto knife to give me straight sides and then to make the corners perfect 90 degree angles. Once complete. I was ready to start on the individual joints.
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Cutting straight edges with the X-Acto knife and the straightedge. |
Joint: Sharp
I cut through the straight-edged rectangle with the knife to the second sheet of paper (TO not THROUGH) and then bent the foam core back on itself to reiterate the cut. I then took the opposite end of the knife (being careful of the sharp edge) and forced a furrow along the line multiple times until the furrow is as deep as the thickness of the foam. Then I rotated the knife in the furrow to mold it into 45 degree angles.
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Furrowing the foam core into a 45 degree angle. |
Using the hot glue to hold the sides together, I folded the foam into a 90 degree angle and glued along the cut line. I allowed the glue to dry before letting the foam core sit on its own.
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Holding the foam core at a 90 degree angle until the glue was dry. |
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The completed sharp joint. |
Joint: Lap
Starting again with the straight-edged rectangle, this time I cut the foam core all the way through to give my two separate pieces. I laid one piece flat on the table and placed the other perpendicularly and flush on top of it. With my knife, I made soft slits where the vertical edge met the horizontal surface. This gave me a line of equal thickness as the width of the foam core. I then followed the lines with a deeper cut to the opposite side but not through it. I "flicked" off the edge of the cut side with a flat head screwdriver being careful not to break the back paper (just taking off the top layer and the foam inside). I ran the hot glue gun on the edge with no foam and then pressed my second piece directly on to the flap perpendicularly from the first piece creating a 90 degree angle.
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The first piece after cutting the edge to equal the width and flicking off the top and middle layer. |
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Completed lap joint. |
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Completed lap joint (you can see how the two separate pieces are joined perpendicularly to one another) |
Joint: Larger Radius
This joint is a little more intricate than the others. Starting with the same straight-edged rectangle, I worked from the center of the piece and cut out 1/8" strips of foam, going about halfway through and removing the top layer of paper CAREFULLY leaving the foam attached. Then I bent the foam closed going past the intended angle. If you are not satisfied with your angle, you can cut out more slits in the foam until you get a good angle. I then hot glued over the notches and set my desired angle.
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Cutting the small slits in the foam board. |
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Completed larger radius joint. |
Simple Box:
With all the joint practice, it was then time to put my knowledge to work and create a box starting out with two squares and one longer rectangle of foam core. Starting out at one end of the rectangle I measured three inches from the edge, and using my straightedge I cut a deep slit. I used the techniques from the sharp joint and made the first joint. I then measured five inches from the new edge and created another sharp joint. I continued the three inches and five inches once more until I had a cube shape with some excess overlap. I cut the excess off with a knife and made a lap joint to hold the two unattached edges together. I then measured the openings of the box on both sides and cut the measurements out on the two square pieces. I then made lap joints from these pieces and hot glued one to its appropriate side. With the last opening I also did a lap joint; however, I did not glue the pieces together! Instead I just made very exact measurements so that the pieces fit together tightly, but were still able to be taken apart when needed. This is important so that I can use the box to hold the breadboard or whatever else needs to be inside.
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Creating the sharp joints for the three corners. |
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First joint completed. |
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Second joint completed. |
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Four joints completed! |
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After assembling the two sides! |
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All in a day's work in the lab! |
Problems:
When working on the larger radius joint, I found it difficult to only remove the top paper layer and accidentally removed some foam. This was difficult because the paper was pre-laminated and therefore very attached to the foam. Use patience when removing this section because you do not want gaps in your joint.
Helpful Links:
For more information about foam core construction: