I want to build a box that is lightweight, but sturdy. At my disposal I have a laser-cutter, which I want to do the cutting.

My plan is as follows, but I have never done this. I have no idea if this will work, so I'm looking for some advice.

I want to cut the box sides out of wood with a laser cutter using notched edges. However, this wood will be thin and therefore will not be able to hold much weight. To improve the weight bearing capacity of this box I propose to add a layer of honeycomb polypropylene to the base and then add another layer of wood to maintain a rigid bottom surface, thus creating a sandwich of sorts. Does anyone think this will work?

Does anyone have an alternative idea?

  • 1
    This is a little sketchy, without a sketch.. If you post a link to a photo or drawing, I (we) can embed it for you until you get enough rep to do it yourself. – HerrBag Sep 26 '13 at 3:32
  • "a box that is lightweight, but sturdy" leads me to think of tin, not wood. – mike Sep 26 '13 at 3:59

Your idea is very similar to how hollow core doors are made.

Hollow Core Door

If you feel a hollow core door is lightweight and sturdy enough for you, then I would say this approach will work for you.

  • If you have a ReStore near you, you can probably find a hollow-core door for $5-10. Cutting one up would be a lot less work than making one yourself. – BlueRaja - Danny Pflughoeft Sep 26 '13 at 17:37
  • In case you didn't know, the success or failure of this sort of construction is strongly dependent on the proper bond between veneers and core. – bcworkz Sep 26 '13 at 23:22

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