Fab-in-a-Box Pop-Up Cards

Gather example materials:

Pop-up cards and/or pop-up books. Many can be found at your local library. 123D is a good place to start for particularly intricate pop-up engineering.

Welcome:

Greet the students and introduce the lesson topic: designing and fabricating custom pop-up cards using CAD software and a vinyl cutter.

Briefly explain what CAD software is and its importance in design and manufacturing.

Show a few examples of pop-up cards to spark interest and creativity.

Context:

Paper pop-ups are a form of engineering that use basic forces—simple pushes and pulls—to fold and unfold dynamic three-dimensional scenes from simple cardstock.

Some of the earliest pop-ups used to make books and other texts interactive, inviting readers to lift flaps, pull tabs, and unfold elaborate spreads tucked into the pages.

Key terms:

Score Line: A line created in the material to make it easier to fold. In CAD software, score lines are typically represented differently from cut lines.

Cut Line: The line along which the vinyl cutter will cut the material. It defines the edges of the design.

Path Editing: A function in CAD software that allows users to manipulate the paths or outlines of shapes and designs.

xDesign Steps:

Click OPEN on the xDesign landing page

Click the “Minimize” icon in the upper right-hand corner of the Search results page

— the results will be repositioned to the right-hand side of your screen so you can see things alongside your xDesign session

[1] Type “Lesson3” in the Search field, [2] press Enter on the keyboard, then [3] click on the blue header bar (to dismiss the Search History panel)

— the Search results will update to show you the PaperPop-Ups template

[1] Drag the PaperPop-Ups template into your xDesign session and then [2] click “Cancel” in the lower right-hand corner of the Search results panel

Click SAVE AS… in the dialog that appears

[1] Type a new name for the component (perhaps add your initials) and then [2] click SAVE

Double-click the “Your Text” sketch in the Design Manager

Press “N” on the keyboard to look normal to (straight at) the sketch

Drag a box around the word “FAB” to select it

Press “Delete” on the keyboard.

Click the “Text” command on the keyboard

Type your initials into the Text box 

Move your mouse around the screen and notice how the text follows.

Experiment with the font type, size, and more, moving your mouse around the sticker to make sure it’ll fit the way you want.

Click the “OK” checkmark at the top of the dialog

— Notice that the text appears at the origin

Drag any point on the text to reposition it to where you want

Click the “Accept Sketch” button to update your sticker

Click “Save” on the Action Bar to save your sticker

BONUS

Edit the “Your Text” sketch again and add other shapes to it using the “Circle”, “Rectangle”, and other tools 

Prepare machine:

Turn the machine on.

Connect to the machine via bluetooth or a USB cable.

Select the appropriate machine from the menu once it appears.

Note: if a firmware update is required, you will need to install this before proceeding.

Prepare material:

Using a low-adhesion mat, line up your cardstock and press it firmly into place.

Line the mat up with the machine.

Push the arrow button to load the mat, centering it between the pressure wheels.

Use the arrow buttons to align the toolhead with the upper right corner of where you wish to cut.

Send file:

The machine will take a few moments to process your file, cutting first and then scoring.

When the machine has finished, press the unload arrow to release the cutting mat.

Post-processing:

To remove your workpiece, turn the mat over so the workpiece is flat on the table. Gently peel the mat off of the workpiece. (This helps keep your finished product flat and intact. Peeling the workpiece from the mat will likely result in torn or curled cardstock.)

Bend and crease:

Gently bend along the mountain and valley folds to create folds.

Once you are happy with these, go back through with more force—or your fingernails or a 3D-printed tool—to create creases.

With your creases in place, carefully fold the whole card flat. Be patient; it’s easy to accidentally bend a crease backwards the first time.

Glue the workpiece to a backer if desired, being careful to line up their center creases.

Decorate:

Add doodles, sequins, googly eyes, or whatever other decorative elements tickle your fancy!

Extensions:

Paper circuits

No soldering required = appropriate for any level! Add copper tape, a coin cell battery, and LEDs to really bring your pop-up card to life. Consider adding a press-tab; when a copper-clad paper “button” is pressed, it completes the circuit to illuminate the bulb.

Discussion Questions:

What can you tell me about your pop-up design?

Why did you choose this design?

What difficulties did you have with CAD and the vinyl cutter?

Did you use letters, shapes or both to create your work?

How did the connections impact your design choices?

Optional Tie-ins:

Mathematics:

Geometry and Measurement: Integrate lessons on geometric shapes, angles, and measurements. Students can apply these concepts when designing their pop-up cards, ensuring accurate dimensions and angles for the score and cut lines.

Symmetry and Patterns: Discuss symmetry and patterns in design. Students can create symmetrical designs and explore how patterns can enhance the visual appeal of their pop-up cards.

Art and Design:

Graphic Design Principles: Introduce basic graphic design principles such as balance, contrast, and color theory. Students can apply these principles to create visually appealing and effective pop-up card designs.

Creative Expression: Encourage students to express their creativity through their designs. They can incorporate personal themes, stories, or messages into their pop-up cards, making each project unique.

Engineering and Technology:

Mechanical Engineering Concepts: Explore the engineering behind pop-up mechanisms. Discuss how different types of folds and cuts can create various pop-up effects, and relate this to real-world engineering challenges.

Technology Integration: Highlight the role of technology in modern design and manufacturing. Discuss how CAD software and vinyl cutters are used in various industries, from product design to architecture.

Career Connections:

Artist: Artists can use CAD software to create intricate and precise designs for various art projects. The skills learned in designing and fabricating pop-up cards can be applied to creating unique, high-quality artwork and exploring new mediums.

Marketing: In marketing, the ability to design custom pop-up cards can be a valuable skill for creating engaging promotional materials and direct mail pieces. These eye-catching designs can help capture the audience’s attention and convey messages effectively.

Book Making: Bookmakers and publishers can use CAD software and vinyl cutters to design and produce interactive elements in books, such as pop-up illustrations. This adds a dynamic and engaging aspect to books, making them more appealing to readers.

Mechanical Engineering: Mechanical engineers often use CAD software to design and analyze mechanical systems. The precision and understanding of mechanisms required in creating pop-up cards can be directly applied to engineering projects, enhancing their ability to design functional and efficient systems.

These career connections demonstrate the versatility of the skills learned in this lesson, showing how they can be valuable in various professional fields.