'Pochita' Paper Model - Chainsaw Man

For this project, I designed and fabricated a paper model of Pochita from Chainsaw Man. The assignment required us to transform a 2D net into a 3D form using Fusion 360 and laser cutting. I chose Pochita because the design combines simple geometric elements (a box body) with more complex features (chainsaw head and handle), allowing me to apply techniques from the readings in a creative way.

Cardstock paper (Letter size) — 3 colors:

1. Orange (body)
2. Gray (chainsaw blade)
3. Black (handle)

Laser cutter (set to cardstock cut + engrave settings)

Computer with Fusion 360 (for parametric net design)

Clement Zheng’s Joinery Tool (for tab insert design, optional but recommended)

Cutting tools (craft knife + ruler, for small adjustments if needed)

Decorations:

1. Eye stickers
2. Black marker

My initial goal was to create a recognizable character while still meeting the requirement of a fully closed form. I divided Pochita into three main parts:

1. Orange body (a box-like shape)
2. Chainsaw head (rectangular prism extended forward)
3. Handle (black curved piece attached with tabs)

I sketched the design on paper and annotated shared edges and dimensions. This planning step helped me foresee assembly challenges and guided the Fusion modeling process.

I created parameterized models for each component in Fusion 360:

1. The body was designed as a closed rectangular box with hidden slots for assembly.
2. The chainsaw head was made with internal locking tabs to connect to the body securely.
3. The handle used tab inserts inspired by Clement Zheng’s Joinery tool, which allowed invisible but strong attachment.

I fully parameterized all dimensions, so I could quickly adjust side lengths and proportions if needed.

Exported the Fusion design as an SVG file.

Added fold lines in Illustrator for engraving (clean fold quality).

Laser cut three sheets of colored cardstock:

1. Orange for the body
2. Gray for the chainsaw blade
3. Black for the handle

Assembly steps:

1. Folded and glued the orange body into a closed box.
2. Inserted the gray chainsaw blade using locking tabs for stability.
3. Attached the black handle with hidden slot joints, making it sturdy without visible tape.
4. Added finishing touches: eye stickers for decoration, and drew the mouth and tail with marker.

The final Pochita model turned out colorful, stable, and fun. The invisible assembly method kept the surfaces clean, and the multi-color cardstock helped represent different parts of the character. Although the hand-drawn tail and mouth were simple, they gave the model extra charm.

Reading Paul Jackson’s Structural Packaging greatly influenced the way I approached my Pochita paper model. The chapter on “Designing the Perfect Net” made me realize the importance of planning shared edges and annotated dimensions before moving into Fusion 360. This step prevented mistakes when translating a sketch of a character into a parametric 3D design. The section on “Common Closures” inspired me to think beyond simple glued flaps. Instead, I explored locking tab methods, referencing Clement Zheng’s Joinery tool, to create hidden slots for the handle and chainsaw blade. This not only improved structural stability but also kept the surface clean, which was important for the visual impact of the model. Finally, skimming “Creating with the System” encouraged me to see how forms could be adapted creatively: a simple box could become Pochita’s body, while different colored papers and small decorative details brought the character to life.

What worked well: hidden slots and locking tabs created a sturdy structure with a clean look.

Challenges: aligning the chainsaw blade tabs required patience.

Improvement: I would refine the body into a more rounded form instead of a simple box.

Pleasant parts: decorating the model with stickers and drawings made the process playful.

Conclusion 🌟:

This project showed me how 2D nets can be extended beyond abstract geometry into playful, character-based designs. By combining principles from structural packaging with creative modifications, I was able to fabricate a stable, colorful, and fun paper model that connects technical skill with personal creativity.