NESTING BOXES
The “Box Class” taken by first year Entertainment Engineering & Design majors requires students, over the course of the semester, to create a series of boxes that nest within each other (much like Russian dolls) while maintaining tight tolerances. Each box is made from a different material starting with paper followed by foam core, wood, and lastly, steel. Knowing that each box relied on the next, a plan was created to form an overarching theme for the series of boxes.
Paper & Foam Core Cubes
Prompt
Using foam core board, construct a box that can house a paper cube with no more than 1/32” gap between nested faces.
Solution
Constructed a box that would offer up the paper cube when opened. A set of hands, mounted to a sliding platform fixed to the door, grasps the paper cube; as the door of the foam core box is opened, the hands are pulled from within and open up, revealing the paper cube.
Place in Theme
Spare part packaging for the Power Cube. Buy N’ Large, the mega corporation featured in Disney's Wall-E, developed a brand identity meant to emphasis the human link between robots and people, hence the hands presenting the Power Cube to the installer.
Wood Cube
Prompt
Using wood, nails, screws, or wood glue, construct a box that can house the foam cube with no more than 1/32” gap between nested faces.
Solution
Built a wooden version of Wall-E with functioning arms, retractable treads, and compartment for the foam core cube. The arms and treads are capable of being tucked inside Wall-E’s body. Head is constructed from foam core; lightness was required in order for head to be driven by a pan/tilt servo system.
Place in Theme
The Wall-E character. Since the compact form of Wall-E is a cube, he fit well into the overall narrative.
Steel Cube
Prompt
Using 10” x 40” 14 gauge sheet metal, construct a box that can house the wood cube with no more than 1/32” gap between nested faces.
Solution
Since the provided sheet metal was not sufficient to completely cover Wall-E, the professor was asked if piano hinges were permitted as a construction material. After receiving approval, three 6’ piano hinges were cut and used to create the edges of the box housing Wall-E. The hinges were bent ninety degrees to form an “L” shape and riveted together to create a sturdy box. The sheet metal was used to reinforce the box and form the abstract shape of a rocket. The metal was weathered using a salt and vinegar spray.
Place in Theme
Wall-E gets a distress signal from EVE that her power core is failing. She will be stranded on a distant planet if Wall-E cannot reach her. Rifling through a junk yard, Wall-E finds a new old-stock power core (the paper box) in its original packaging (foam core box). Using rusty scrap metal, he builds a rocket (the metal box) to find and rescue EVE.
