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Stacking Boxes

119 opens
17 copies
Beyond Design

Project by

Beyond Design
Chicago, Illinois

General Information

Simple square boxes designed to minimize material waste and cut time. In this instance of the design I made one set from HDPE and expanded PVC. The other set is HDPE with cork and acrylic.

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Material Description Price
40% Light Transmission White Acrylic Sheet

40% Light Transmission White Acrylic Sheet

Dimensions: 8 in × 12 in, Thickness: 1/8 in

Black HDPE Sheet

Black HDPE Sheet

Thickness: 3/4 in, Dimensions: 8 in × 12 in

Grey Expanded PVC Sheet

Grey Expanded PVC Sheet

8" × 12" × 1/8" Grey Expanded PVC Sheet(Do not use)

Natural Cork Sheet

Natural Cork Sheet

Dimensions: 8 in × 12 in, Species: Cork, Type: Sheet, Thickness: 1/8 in


Mill box walls

Use a 1/8" square or fishtail endmill to mill the walls for the box set. A 3/4" or taller material will be best for making a functional box. Use double sided tape to keep the nesting sections from shifting

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Mill box lids

Choose a 1/8" material to use as your lid. Expanded PVC cuts quickly and comes in good colors. A translucent acrylic also works really well.

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Mill box bases

Mill the box floors from either the same material as the top, or choose one that compliments it well.

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If everything cuts correctly, no glue is required for assembly. The base fits into the side with the small ledge cut into it. For extra durability you can squeeze a small amount of super glue into this area.