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I’ve been seeing this a lot lately: use a laser cutter to make many cuts, allowing the wood to bend where the kerf has been removed. This is also known as a “living hinge” and has been popular, albeit labor intensive, since the advent of tablesaws (or earlier? Post a link). The above Arduino + radio enclosure was made from walnut by Shaun Crampton (via Hackaday) and he also offers a detailed tutorial for making a similar box of your own.
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Very beautiful, but I’d suggest <a href="http://www.craftsmanspace.com/knowledge/keyed-mortise-and-tenon-joint.html"<tenon keys rather than screws for attachment.
Comment by John Personna — June 12, 2012 @ 5:08 pm
oops, sorry, too fast on the html.
Comment by John Personna — June 12, 2012 @ 5:08 pm
I think the screws look much more noticeable in the photo than in real life. I might have to give alternative joints a try though. That keyed tenon looks like it’d stick out quite a way on a small piece like mine. I wondered about gluing on the end caps and then using a little peg (like on the top) to hold the bendy piece in place. Or, maybe using glued-on magnets to hold the sides down so it’d be easy to remove for maintenance.
Comment by Shaun — June 12, 2012 @ 11:11 pm