In this instalment, I will show you how to build a simple project box out of Sintra using the KRMx02 CNC.

This box has an outside dimention of 4" deep x 4" wide x 2" tall.


The Design

The top and bottom components for this box is 4" x 4" made from 3mm Sintra.

They are cut from a 4.5" x 4.5" piece of stock.

Top and Bottom Drawing Files

They are cut at 25IPM using a 1/16" up spiral end mill.

You will need two of these.

The sides are are 3.625" x 2" with .1145 dimples added to each corner in order to slip into the slots on the top and bottom components.

They are cut from a 4.5" x 2.75" piece of stock

Side Drawing Files

These are also cut at 25IPM using a 1/16 up spiral end mill.

You will need 4 of these.


Milling the Top and Bottom Componenets

Install the 4.5" x 4.5" piece of 3mm sintra on the machine.  Don't forget the water board.

Zero the machine and cut the part using the following Gcode.

Sintra Project Box Top and Bottom Gcode


The finished part should look something like this.  Again, you will need to mill two of these.

Once you removed the waste stock, you will have to clean up the tabs.  I find it easiest to use a small pair of wire cutters then sand the edges with 220 grit sand paper.


Milling the Side Components

Inset the 4.5" x 2.75" piece of stock on the KRMx02 as shown here.  Again, you will need a piece of waster board under the stock.

You should not need to zero the stock, unless you are using some other material for the waster board.

Sintra Project Box Sides Gcode

The part should look like this.  You will need to make 4 of these.

Be sure to clean the tabs.


Box Assembly

With all six compoents, you are ready to assemble your project box.

The sides slip into the groove on the bottom component, as shown here.

The top componenet is then added.


Securing the Box Components

There are several ways to secure the components.  One way is to add a standoff to the bottom component.

On this one I even added some feet.

Once you have a stand of installed, its a simple matter to add a screw and secure the top component to the assembly.

Yet Another Way

Take 4, screws and acorn nuts.

Note that the screws should be able to protrude through the thickness of your box.

In this case they are 2-1/2" long.

Stick the screws through the holes in the top component and the bottom component.

Secure with the acorn nuts.



That's it.  You can add the holes for your application as you cut them out, or you can cut them after the box components have been created.

It is also very easy to scale this component profiles for larger or smaller project boxes.