Download Files

Our Template Sheet is a PDF designed to fit standard 8.5 x 11 inch paper.  For direct cutting, we provide a Flat Pack SVG files of just the parts.  The Fusion 360 archive file is available to download in STL, STEP, OBJ, and other formats. The F360 archive contains original sketches and editable user parameters for creating custom sizes. 

Enclosure Template

The enclosure is made out of 5 pieces that snap fit together via tabs and slots. Two main side walls feature slots that allow tabbed pieces to snugly fit together. Each part is designed to secure a component or become a structural piece of the enclosure. The template for this design was made in Autodesk Fusion 360 with user driven parameters so it can be customized to fit specific projects. 

The enclosure is similar to cases that are designed to be made on a laser cutter. This design doesn't require screws or glue because of the tight tolerances in slots. Cardboard has a bit of flex so it can compress and fit through tight openings. The tabs extend beyond the slots to accommodate for slop during the cutting process. 

Paper Template

We designed the enclosure to be made out of cardboard. This is the type of cardboard most commonly used by UPS shipping boxes. It's around 2.6mm thick. If you're using a material that is thinner or thicker, it might not fit perfectly when assembling. The tabs and slots are designed for ~2.6mm clearances.

Cutting Parts

The template can be printed with an office/home inkjet printer. This can then be transferred to cardboard by cutting each part out and tracing it with a marker or sticking it to the surface. Either way, you can cut it out by hand or use a vinyl cutter like a Cricut or Silhouette.

For Inkjet Printers

If you're using an inkjet printer to print the template, you can use common office paper. Use scissors to cut around the outline of each part. Then, use a knife pen to carefully remove the inner cutouts like the slots and mounting holes. Place each part over a piece of cardboard and trace the outlines using a sharpie, marker, pen or pencil. Once the parts have been transferred to cardboard, cut them out using a retractable blade or x-acto knife.

For Cutter Bots

A laser or vinyl cutter can help speed up the process so if you have access to one definitely take the opportunity to learn how to operate it. The SVG and DXF files contain the vector shapes for precise cutting machines. Each machine has a different software for processing these files so we won't cover them in detail here.  

Explode Wireframe

This animated GIF showcases the assembly of the case. Here's how the pieces fit together. Start with the left wall and insert the tabs from the three non-slotted parts. Then, insert the longer part to the bottom. Fit the remaining tabs into the slots of the right wall to hold everything together.

This guide was first published on May 30, 2018. It was last updated on May 30, 2018.

This page (Cardboard Template) was last updated on May 11, 2018.

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