I'm trying to gather some insights on producing small boxes, ideally in batches of around 25 to 30 at a time. The dimensions I'm aiming for are approximately 4"x4"x6". The design should include a removable lid, and I'm considering a sliding top similar to a pencil case to avoid needing extra hardware. Has anyone here had experience with box production like this? I'd appreciate any suggestions or ideas to help streamline the process! We've experimented with various container options but are starting to lean towards wooden boxes. I've looked through Matt Kenney's book and found some inspiring examples. What do you think would be the quickest and strongest method for joining the pieces together?
4 Answers
I recommend prototyping a solid design first. Once you have that, you should machine all parts in batches. Set up for cutting sides first, do all of those, then switch to the bottoms, and keep going like that. Don't forget to cut a few extras just in case!
I ran a similar project but with smaller boxes (2x2x6). I mitered and pinned the corners, using the bottom for extra structural integrity. That method worked well for my needs, so you might consider it if it fits your design.
For a fast assembly, consider using 1/4-1/4-1/4 style joints with the wood planed to match your blade thickness. This method can produce a nice finish and requires minimal setup—just an FTG and a hi-atb blade with a hook angle of less than 10 degrees should do the trick. You can even do the sliding top at the same time and just sand the shoulder for a smoother operation.
I suggest getting a miter fold bit for your router and constructing a jig that allows you to cut the sides from prepped stock. If you can slice it off a larger board as you go along, a bit of prep will save you a lot of time in the long run. Seriously, a day or two setting this up can save you a week of actual work!
Totally agree! A finger hole in the lid could also be handy depending on what's inside the box. A couple of jigs for stock cutting and joinery would make the process even smoother.