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DXF Files

DXF Tutorial Videos – Only customers who have purchased a DXF file can access these videos.

How to fill out the DXF file order form

Why use DXF files?

Drawing accurate parts for box jointed boxes is a time consuming task. When you have finished and have made one mistake…………CNC machines are not forgiving!

How will you clamp it? Ideally every joint should be firmly clamped simultaneously. How many ‘F’ clamps do you have? Can you hold all the joints at the same time? Will you distort the box when you clamp it?

‘Box Jaw’ is our proprietary rotary clamping system. Every DXF file has all the clamp parts included in it as standard. ‘Box Jaw’ is made from the same material as the box. They are customised for your box at the time of drawing. Clamps are reusable so make as many boxes as you wish.

Each part in the drawing is bundled into a ‘block’ so nesting tasks are a cinch. The parts are surrounded by spacers, so obtaining the optimum spread over the material means less waste.

Extensive use of ‘layers’ means logical grouping of cutting operations across all parts.

Don’t have a vacuum table? No problems. Our DXF files include features that simplify and optimise material and part holding to the next level. Never cut out holding tabs again!

Increase your productivity by up to a third with our mirror option. Build and finish 2 boxes in one operation!

At you are in control. Specify your sizes. Start your production line!

Every file purchase includes access to our ‘How To’ video collection:

  •                 The CAD/CAM process – Including tips on beating tool deflection for more accurate parts.
  •                 A practical demonstration of CNC cutting a set of parts.
  •                 A demonstration of how to assemble and finish a box.
  •                 A demonstration of how to assemble a mirrored box.

A quick Video

How to fill out the DXF file order form

It is important to provide accurate information when filling out the DXF order form. Following is an explanation of what the fields mean and how they interact with each other.

What size box do I need? If you are putting your box into a particular space, say a shelf with dividers, you should leave some social space. Eg: I want a box that will fit into a space that is 500mm deep, 250mm wide and 250mm high. The DXF file you order should be 500mm long, 245mm wide and 245mm high. IE: 5mm less on the width and height values. If you were to order a file for a box that matched the space, when the box is slid out, a vacuum would be created, making removal difficult.

If your box is for something specific, consider enough space to allow your hands to pick that thing up. Also you can select ‘Inside Dimensions’ and BoxHeads will add the material thickness to allow for this.

Length (mm): Some refer to the length as ‘depth’. If your material has a grain, it will align with the length of the box. Must be a whole number.

Width (mm): This is the short side of the box. If you have specified handles (most do), they will be placed on this surface. Must be a whole number.

Height (mm): The overall height of the box. Note: This does not include a lid (if any). If you intend to use a lid, the box will higher by the thickness of the lid. Must be a whole number.

Inside or Outside Dimensions: Indicates whether material thickness needs to be compensated for in the overall dimensions of the box. Select one.

Target Joint Pitch (mm): The length of a joint. This is used as a guide when calculating the length of the joints. BoxHeads calculates the nearest odd number of joints to the Target Joint Pitch value. The smallest number of joints will be three. EG: Say you order a box 450mm long 350mm wide and 150mm high and the Target Joint Pitch is 50mm. The joints on the length side will be 50mm, 9 of. The width 50mm, 7 of. The height 46mm, 3 of. The difference in the height joints is the thickness of the material needs to be taken into account. The minimum Joint Pitch is material thickness x 2. Must be a whole number.

Material Thickness (mm): Most plywood thickness varies slightly over a sheet. IE: The actual thickness will be different to the nominal thickness. It is important to measure your material at various points to determine the largest value, down to 0.1mm. A digital vernier is useful here. The largest value should be entered in this field. If you can not do this you should increase the value of the Box Joint Overhang. (See below). Must be a number with one decimal place. Eg: 12.3

Box Joint Overhang: The amount a joint will overhang it’s adjacent face. To achieve a finish where the joint can be seen though not felt, it must be trimmed down after the box has been assembled. This is normal practice. BoxHeads recommends a value of 0.3mm. If you have not been able to measure your material, it would be wise to enter a larger value. Must be a number with one decimal place. Eg: 0.3.

Handles: Most boxes have handles though you can choose not if you wish. If you select yes, you can still choose not to cut them during the CAM process. The standard handle size is 75mm long, 25mm wide with a fillet radius of 7.5mm. They are placed 20mm from the top of the box. These values are configurable. Contact us if you require different values. Select either.

Cutter Diameter (mm): At BoxHeads we always use 2 fluted straight 4mm carbide bits. You can specify a different value if you wish. Affects placement of holding tabs and Mirrored Box layout. (See below). Must be a value with two decimal places.

Lid Style: Currently two lids styles available: Plain is a simple lid whose grain aligns along the long side. It has eight locating lugs underneath (two on each corner). It sits on top of the box. Plain with backing: Similar to the plain lid though the locating lugs are replaced with a part whose dimensions are the same as the the inside for length and width of the box. Indexing holes allow easy assembly through the use of locating dowels. This lid style can be useful if your material is likely to warp. For single boxes, at least one lid is required during assembly to stop the box being distorted by the straps.

Lid Index Diameter: If you have chosen the Plain lid with backing you can specify the diameter of the index holes. The default value is 6.00mm. Must be a value with two decimal places.

Part Spacers: All parts include part spacers. They are used as a guide during the part nesting process either in CAD or CAM. They are not cut. The default value is 12mm which is useful for a cutter diameter of 4mm. Must be a whole number.

Mirrored Boxes: To reduce assembly and finishing time by up to a third, two boxes at a time may be built by opposing the two. The center line is partially cut, leaving four lugs which are removed after assembly and finishing. This is a cost option ($5.00AUD). Select either.

Go to the DXF order form

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