Packaging (Cardboard) Folding/Unfolding Material Workflow

[nathan.skalsky]

Hi All - I thought I'd share this and also see if anyone had suggestions for a better folding / flattening workflow.   I've been making a few sample projects and sending them to family/friends.  To make shipping easier and learn new things I decided to include a shipping insert so that the completed assembly (here a flat-pack ergonomic laptop stand) can be easily inserted into a USPS priority mail flat-rate box.   

I have done a couple of these in foam (shown) however I'm awash in cardboard boxes that I think would be good to reclaim here.   

Using Assembly Joints to Fold/Flatten:   I mocked up the cardboard insert using joints so that the "3d" folded cardboard assembly can be unfolded.  When its unfolded I join the bodies together and use CAM 2D Trace to cut out the profile.   Other suggestions?

Thingiverse Project Link

Thanks!

-Nathan

[jeff_strater]

Hi Nathan, good to hear from you here!

I've used the Revolve Joint approach as well, in some origami-type playing around designs.  You make separate components for each piece of cardboard, then unfold till flat.  I never took it all the way to join them back together, but that's a good step.

This method, though, does not account for the folding deformation at all, so you may have to make pieces slightly bigger than necessary to get it just right.

Unfortunately, I don't really know of any other method to do this just now.  You'll have to wait for Sheet Metal (interesting requirement, though:  Can a sheet metal product be adapted for folded cardboard?  I don't know why not).

Jeff Strater (Fusion Development)

[nathan.skalsky]

Thanks Jeff -  sounds good, I'm also going to check out this ExactFlat plugin I see on the community calendar.   

good point on deformation - I made the peices oversized anyway with the idea that they'd flex and develop a bit of spring/pressure to stay put in the box.

BTW: here is the thingiverse link in case people are curious what the wood peices are (not sure I'd figure it out) http://www.thingiverse.com/thing:810295

-Nathan

[darran]

Hi Nathan, this packaging looks amazing. I'm curious, how did you go about actually fabricating the foam insert? I'd like to do something similar, albeit using that egg-shell carton material.