For the press-fit assignment, I wanted to make a cube.
I made the design in Inkscape. I was not sure how thick the cardboard is, so I did not make specific measurements (corresponding to a specific size), instead “guess-timating,” as we like to say in the world of biology.
I used the Kern laser cutter in the Harvard Physics/SEAS machine shop to make my design out of cardboard.
The pieces came out pretty well and I was able to assemble the cube from 6 panels.
The pieces did not fit as snugly as I would have liked. Also, the protrusions were a bit longer than they should have been for a perfect cube.
Some of my classmates then measured the thickness of the cardboard and although the cardboard we used seemed a bit variable in terms of thickness between pieces, the thickness was found to be about 1.7 inches. It was thus recommended to make a 1.5 inch (3.85cm) joint for a snug fit.
One of my colleagues questioned the utility of my cube. In response, I demonstrate that my press-fit cube makes a great hat.
Moreover, one could store things inside the cube hat whilst wearing it, thus adding hidden functionality to an already stylish accessory.