Everything went wrong but I still designed this custom articulated storage box

I needed a custom storage box with some trick articulation, but the universe wanted to fight me every step of the way. I got there in the end, and levelled up with my design skills. This is that story.

A summary of the curse:
Plywood changed composition and would not cut cleanly
Laser cutter belt became loose and then detached
Repair of laser cutter was stupidly awkward
New problems introduced after repair which needed calibration
Laser cutter not square
Power outage once everything was actually working
3D printer decides to randomly reset for the first time, mid print
2nd choice 3D printer decides PETG will not stick no matter what
Rain on the day I wanted to paint
Broken blade trying to shorten a screw
Rain now that I’m done
While I was filming the last shot, my dog stole a new pillow and ripped it to shreds

0:00 Introduction

0:55 The scenario

2:27 Design concept

3:29 CAD model

4:33 Manufacturing round 1

6:52 Redesign

7:34 Round 2: The curses begin

11:01 Making everything for the third time

14:14 Final assembly

16:31 Finished product

17:08 Conclusion

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[Garoninja]

This is not helping me convince myself I don't need a laser cutter. I hadn't even considered custom boxes

[imfabs]

Need to use an oscillating tool blade with carbide or titanium teeth for cutting the screws. Alternatively a good pair of side cutters

[Nifty-Stuff]

Just gotta say: Michael, that's a SUPER smart design!!!

[FedeHippo]

Maybe paint the inside white instead of black? Would be way easier to find black lenses at night.

And for extra ease of use, install some LED strips in the same color as the flashlight you showed at the start

[RPMiller]

You should totally add some red LED strips for lighting so you can see inside the box for things like caps and the like. I know you have the torch, but some integrated lighting would be so chef's kiss.

[erlendh]

The black lines are phenolic resin-based glue, often classified as 'outdoor use.' The transparent glue (5-ply in your case) is water-based and often categorized as indoor ply. The resin chars much more when being burned, making the laser less efficient at cutting through.

[thenextlayer]

Great video. Love seeing that you have the curse too. Check your email btw!

[grantmills]

P.S really enjoyed the design process, from identifying the design requirements through to the final product.

[gameboys]

Today I learned that acrylic under stress and isopropyl alcohol react together and the piece will start cracking from the stresspoint. Had to remake like 40% of the parts....

[iteerrex]

My most cursed project was a complex electrical board. It was a few years ago (before pcb-way), so I was building it by hand. Long story short, It just would not work, and after days of testing and tracing 🤦‍♂️, I built a new one from scratch. So yea the troubles and triumphs of RnD is real.

[GeorgeGraves]

"the finish was exactly what I was after" - Ha! I'm going to use that line when I make something that looks like poop. Just say "That's what I was after!".

[jimbober]

Yeah, lots of frustration involving freecad behaviour! Lol

[grantmills]

Every project I attempt goes like this ! I do not have a workshop and use the kitchen table. I do more damage packing and unpacking tools and materials during constructon than from using the project. 🤓

[brettjamesy]

Wait till you hit your 60's... a new level of frustration presents itself. On a brighter note, after you wake up from a nap, all is forgotten.

[naikymen]

My making journeys are only about curses and frustration. One time i struggled to get a structure square, only to realise that the extrusions were bent! I enjoy working with constraints but there is a limit to everything. Nice drawers!

[izzieb]

I am my parents most cursed project and I'm unfortunately still a work in progress.

[jurijsmisnakovs]

It's interesting that I have the exact same CO2 laser. While working on it, I've often wondered what would happen if the Y-axis belt were to break. Now I know! Thanks for the answer :D :D :D

[scottschlesier]

Growth as a maker 😂. Do you level up based on number of four letter words uttered in a project.

[thedabblingwarlock]

Well, there was one time where I messed up and managed to take a client's site down for 12 hours.

That was not a fun day.

[Hilmi]

Tired, fed up and working late into the night. Sounds like a typical night of astrophotography. Welcome to the darkside and say goodbye to all disposal income as you buy more and more telescopes. Also, the clouds come with every new Astronomical purchase