Laser Cut Boxes: Step-by-Step Guide

Finger joint boxes are a popular choice for most people starting with a laser cutter – and for good reason. These boxes can be used for organizing things (stationary, craft supplies, jewelry) and even packaging gifts and products.

However, many beginners hit a snag when they dive into box-making without proper research or practice. The result is a box that doesn’t fit together properly. This happens because factors like kerf adjustments, material thickness, and design precision are often overlooked.

This guide explains the entire process of making laser cut boxes, from designing to choosing materials, cutting, and assembly. Stick around, and you’ll have everything you need to master this rewarding skill!

Step 1: Designing the Laser Cut Box

This phase is the foundation of the project and the most critical step. It’s also where many people tend to make mistakes. You can either use online box generators or create your design using graphic design software.

Considerations When Laser Cut Box Design

When creating a design, you need to focus on four key factors: size, material thickness, kerf, and tab width.

1. Size of the Box

This refers to the geometric dimensions of the box: its length, width, and height(depth). These measurements depend entirely on the intended use. Since this is a finger-jointed box, you’ll need to account for either inside or outside dimensions. But this distinction is particularly important when using online generators.

2. Material Thickness

Material thickness defines the interlocking edges of your box. If the edges are designed too deep relative to the thickness, the box corners will stick out. On the other hand, shallow edges result in loose assembly.

Accurate measurements are very important for design. You can use calipers for manual measurement. Material sheet packaging also has pre-specified thickness – use that.

3. Kerf Width

Kerf width is the width of the slit created when the laser cuts through the material. Although it’s just a fraction of a millimeter, if you fail to adjust for kerf in design, that can result in loose-fitting joints. For more details on laser cutting kerf, check out our article for more insights on the subject.

4. Tab Width and Depth

Tab width and depth define the interlocking sections of the box. Tab depth should match the material thickness (with kerf adjustments), while the width depends on the overall size of the box.

Narrower tabs create more interlocks, which can make the box stronger, but only up to a certain point. Conversely, wider tabs mean fewer interlocks, so you’ll need to leave enough material at the corners to support them. 

A general rule is to ensure tabs are large enough to maintain stability but not so large that they disrupt the visual harmony of the design.

Websites to Get Laser Cut Box Designs

An easier option for creating laser cut box designs is to use online generators. Here are some apps and websites you can explore:

Box-o-Matic

This is an IOS-based app only, where you can generate designs for laser boxes. The app has multiple box templates and customization options but only a limited are available in the free version. Note that it works exclusively on Apple devices.

MakerCase

MakerCase is a web-based generator for creating laser-cut design files. You can choose from five different box templates. All you need to do is enter the desired parameters and download the output in SVG or DXF format. These files can be imported into laser control software for immediate use.

Cuttle

Cuttle.xyz is a valuable resource for laser cut project templates. They have multiple box design templates with extensive customization options. You can adjust the dimensions of your chosen design and download it for use.

DesignFind

DesignFind is a community-driven platform where xTool owners and other laser cutting enthusiasts share their design projects. Here, you’ll find a mix of paid and free designs, including many laser cut box templates.

Etsy

Although Etsy is primarily known for handmade items, it’s also a great source for digital downloads. You’ll find a wide range of laser cut files, including designs for boxes.

Step 2: Selecting the Material for the Box

After finalizing the design, the next step is choosing the right material. The material you select depends on the purpose of your project, the aesthetics you desire, and your budget. 

Some common options for laser-cut boxes:

Cardboard

Cardboard is the most affordable option, used for creating laser-cut boxes for packaging. Its types – paperboard and corrugated fiberboard – are lightweight and easy to cut. 

Wood Plywood

Plywood is a solid and sturdy option for making durable boxes. It is great if you’re looking for a natural wood texture and a more solid structure. Plywood comes in different thicknesses, with 3 mm (1/8 inch) and 6 mm (1/4 inch) being the most common for laser-cutting projects. 

Besides plywood, MDF is also a great option. Check out xTool material store for different types of plywood sheets. 

Acrylic

Acrylic is an excellent option for creating aesthetic boxes, those used for gifting, jewelry storage, or decorative purposes. Its highlights are a glossy finish and vibrant colors that make it visually appealing. Acrylic sheets are available in multiple thicknesses, but 3 mm (1/8 inch) is the most versatile and commonly used for laser cutting.

Step 3: Getting a Laser Cutter 

Next, you need the right laser cutter for the job. Both CO2 and diode lasers can cut cardboard and plywood sheets efficiently. 

In fact, diode lasers, like the xTool S1, are a cost-effective option for cutting such thin sheets. But CO2 is best for cutting wood and clear acrylic, especially. Among the desktop laser cutters on the market, the all-new xTool P2S is the best.

xTool P2S: Best CO2 Laser Cutter for making Laser Cut Boxes 

If you need a machine capable of cutting all the box parts in one go or something suitable for commercial use in small businesses, the xTool P2S is the perfect tool.

Top product reviewing sites have declared xTool P2S as the best desktop CO2 laser on the market. It has remained a top-selling product on Amazon (2022–23) and garnered multiple renowned industry awards, including the Red Dot 2024 winner for best laser.

P2S comes with a 55W CO2 laser module that’s capable of slicing through 18mm black walnut and 20mm acrylic in a single pass. It can engrave materials as fast as 600mm/s.

It has a large bed size, measuring 26 by 14 inches, which is expandable up to 118 inches. For instance, if you want to cut out parts from a long sheet, its auto-passthrough technology lets you feed the sheet into the machine, and it efficiently completes the job.

With a powerful machine like this one, safety can be a concern. But xTool has made it extremely safe with a fully enclosed design and a translucent, laser-filtering lid. The machine locks during operation and includes a multi-warning system that notifies you when the temperature gets high. Most importantly, it has an inbuilt air-assist system to prevent burn marks on thin wood sheets.

Step 4: The Laser Cutting Process 

Connect your laser cutter to your PC and turn on XCS (xTool Creative Space). Import the design file into XCS and ensure that all dimensions in the design are correctly adjusted according to your use case. Next, feed the material into the laser cutting machine.

The xTool control software includes a material library that automatically suggests the optimal settings based on the material and its thickness. You can choose the material type, and input the thickness, and the software will handle the rest. If needed, you can customize the settings for better precision. 

Step 5: Assembly and Finishing

For assembly, follow the design instructions carefully, especially if they specify the front, back, top, and sides. Lay out all the parts in their respective positions to avoid confusion.

For finger joint boxes, it’s a good idea to perform a dry fit first. Assemble the box without adhesives to ensure all edges align properly. If any edges protrude, lightly sand them for a smooth finish.

Usually for wood boxes, most users just prefer a dry fit only. But if you want to permanently join with adhesive, select the appropriate type for the material:

• Use wood glue for a strong, durable bond in plywood.
• Apply acrylic cement to create acrylic boxes
• Hot glue works best for cardboard.

Apply the adhesive sparingly to prevent excess from spilling over the edges. 

In most cases, these boxes are appreciated in their natural tones and textures. However, for plain wood boxes, you can customize the finish with paint, stain, or varnish.