Make a Parametric Cardboard Shelf

In this project, you’ll learn how to design and build a stylish shelf using cardboard and laser cutting! This shelf is parametric, which means it can be customized easily by changing the design in Fusion 360. It’s perfect for displaying 3D printed objects or small collectibles.

3D Design Software – Autodesk Fusion 360 (or similar)

Cardboard sheets – 5mm thick

Laser cutter

✂️ Craft knife or cutter

Glue – white glue or hot glue works

Drill machine and drill bits

Screws and washers – for mounting

Screwdrivers

Start by sketching out a few shelf ideas. Choose your favorite design before moving to Fusion 360.

Open Fusion 360 and start modeling your shelf. We’ll build it using surface modeling tools.

Use Loft to connect three different sketches and create a 3D surface. Then use the Patch tool to turn it into a solid body.

On the back of the model create a new sketch to draw the curve using a spline tool so you can get fingers for finger joint afterwards. Make sure the spacing matches twice the thickness of your cardboard.

Extrude the back of the shelf. Use two layers of cardboard to make it strong.

At one end of the shelf, sketch a rectangle and turn it into a surface. Use the Rectangular Pattern tool to copy this shape across the shelf, spaced at 2x the cardboard thickness.

Use the Split tool to cut your main shelf body into many slices (cross-sections).

Hide alternate slices so we can work with fewer shapes at once.

On each visible slice, sketch and project the edge so you can later cut it from cardboard. Then extrude these sketches into flat pieces.

Use the Combine tool to make slots in the back wall for each cross-section to fit into.

Make another layer for the back—this one will hold special connectors (called butterfly joints).

Split the back into four parts and design butterfly joints to hold the back together like puzzle pieces.

Export all your sketches as DXF files for laser cutting.

Open the DXF files in Illustrator (or similar software). Add numbers to the parts and arrange them to use as little cardboard as possible.

Import the files into your laser cutter software and cut out all the pieces.

You’ll need two layers for each cross-section and back panel. Stack and glue them together.

Use the butterfly joints to connect the four back pieces into one strong back wall.

Slot all the cross-sections into the back panel. Use glue to hold everything together.

Leave your shelf to dry for at least one day.

Drill 4 holes through the back, then use screws and washers to mount your new cardboard shelf on the wall!