Laser Cut "Flat Pack" Parts

Kresty's build is based on Kresty's flat pack, rearranged for laser cutting.

The flat pack files are in the RebelDroids files section.

The laser cut flat packs consist of parts cut on 1/16" (1.5mm) and 1/8" (3mm) styrene (polystyrene) and 2 additional translucent diffuser parts.

Cutting Instructions

Each sheet has a PDF file set an appropriate size for the parts (primarily 18" x 24", but some are smaller.) Some laser cutter drivers are sensitive to the sheet sizes, so you may need to use care with the print settings.

All sheets have a scale to ensure that the parts are printing at 100% size.

Optionally, sheets could be printed on paper and used as a template for hand-cutting.

Each sheet consists of 0.1pt RGB #000 black lines for vector cutting. The raster shapes in other colors should be ignored and not cut.

Each sheet has a 0.1" (2.5mm) margin around the edge to allow for positioning error, but I'd recommend checking before cutting anyway! Most lasers will let you run a preview at 100% speed with the lid open before doing the cut at the slower cutting speed.

Laser Sheet A

1/16" (1.5mm) Styrene Sheet, 24" x 12" (610mm x 305mm) Vector cut the RGB #000 Black 0.1pt lines, skip all other colors and raster shapes.

Parts:

C Band - (Needed for tall height only) 4 halves (may need trimmed for installation), expect 2 layers
G2 Band - 2 one-thirds sections (may need trimmed for installation), allowing 2 layers
G2 Band - 2 two-thirds sections
I Grill - 1 half section
L Window Strip - 1

(Optional E² E Band square - Kresty used printed round caps instead)

Laser Sheet B

1/16" (1.5mm) Styrene Sheet, 19" x 11" (482mm x 279mm) Vector cut the RGB #000 Black 0.1pt lines, skip all other colors and raster shapes.

E1 - half of E band (top/bottom edges will need filed)
E2 - half of E band (top/bottom edges will need filed)
I Grill - 1 half section

Laser Sheet Parts

1/8" (3mm) Styrene Sheet, 24" x 18" (610mm x 457mm) Base

1 A base
8 B supports (either normal or extended height)
4 C half bands - Optional extended height lower band
1 D ring - Optional for extended height build
2 E half bands
1 F ring
2 G third & half bands
1 H ring
2 H1 half rings
2 I grill halves
18 J grill rib halves (for 9 J rings)
1 J-top grill ring.
2 K half rings
1 L window strip
1 M Top Ring
11 Vanes for top fan

Diffuser (translucent)

2 Main grill diffuser halves
2 Window diffuser halves

Optional:

8 E² E Band squares (instead of 3D printed round parts)

UNDER CONSTRUCTION, SORRY!

Back to Kresty Style Build guide page.

Notes

In my version I used the Laser Cutter (could use a CnC) to cut the vanes. If you want to print the vanes, you can get the 3D files for those from Savage's Files.

I built mine with an extra ~1" riser below the bottom sloped section, so there may be slight differences between the drawings, my photos, and the way it should be built.

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Fusion Generator:Kresty Style Build:Flat Pack

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