Wooden Enclosure Box

During the design phase of the research study, laser-cut plywood boxes were made to store and collect survey cards. These were very well received by advisors, leading to the idea of creating something of similar look and quality for claimants to use.

Initially the intention was to construct a box which could contain the square diary cards, digital camera and a MicroUSB mains charger. However, the charger’s dimensions would have required quite a deep box and would make the physical PIP Kit heavier. After testing the cameras, it was realised that their rechargeable batteries held sufficient power for the small number of pictures likely taken – even over 3-4 weeks – if starting fully charged. So the need for charging devices disappeared and the box’s minimum depth was determined by the camera’s own physical dimensions.

Photograph of the PIP Kit wooden enclosure box being laser cut from 3mm birch plywood - the scores for the living hinge can be seen

Wooden “living hinges” provided a way to keep the lid attached to the rest of the enclosure, reducing the number of independent parts. The box design was largely based on Flex Box – A wooden box with a living hinge (by 4volt) which itself was a remix of Folding Wood Booklet (by SNIJLAB), both published on the Thingiverse website.

These and the derived PIP Kit wooden enclosure design are licensed under the Creative Commons – Attribution – Share Alike license. The designs assume 3mm thick plywood. The final wooden enclosure design is available to download. The box sides were set permanently in place using PVA glue and clamped for a few hours until the joints had dried.

Cut foam inserts ready to be glued into place inside the assembled wooden box

There is additional information on the assembly, 15mm and 30mm thick “pick and pluck” pre-cubed and 5mm neoprene foam inserts and elastic cord in the PDF “Materials for PIP Kit’s Laser Cut Items” downloadable from the support materials.

Elastic cord was put in place through two holes in the base, and knotted inside (and hidden by the foam above). The foam and plywood cover plate were held in place with hot melt adhesive using a glue gun.

Three made-up PIP Kit boxes ready for use

The cover plate included a small cut-out to make it easier to pull the camera out using a finger.

Multiple PIP Kit wooden enclosure boxes were made to ensure that multiple claimants could be supported at the same time.