Here we will work out how to design this from scratch using either 3D modeling, or by drawing up in Carbide Create (or any other CAD or drawing program).
This is easily drawn in Carbide Create as a pair of nested rectangles — one the width and depth of the box, the other width less twice the stockthickness, depth less the stockthickness.
We will use the following dimensions for the first iteration of the box:
Toolpath assignment will be the bare minimum necessary to cut parts out — adding tabs or additional geometry to cut as a pocket down to tab depth will be left as an exercise for the reader (Note that doing so is pretty much required to actually cut this in a reasonable period of time, since for expediency a very small endmill will be used).
Naturally job setup is for the StockThickness of 0.25in:
We need to remove half the depth of StockThickness at each end in a rabbet which allows for the full thickness of the ends (so again StockThickness), as well as cutting a full length rabbet for the bottom, and a stopped rabbet for the lid at the back of the box.
Drawing this up in Carbide Create is a matter of 3 rectangles: one the width of the height of the box, and the depth of it, a second stacked on top which has the width reduced by the rabbetthickness for the length of the rabbet, and a smaller inset one which is narrower by one and a half times the stockthickness, and shorter by twice that dimension as well.
For the ends we need a cube which is BoxWidth less StockThickness wide, BoxHeight tall (for the back, and if there is a lid, BoxHeight less StockThickness tall and Stockthickness high with suitable rabbets:
Lastly there’s the lid which is much the same as the bottom, except that it is narrower than BoxWidth by Stockthickness, shorter than BoxDepth by rabbetwidth, and of Stockthickness with a rabbetwidth rabbet around the sides and at the back, and with a divot (or hole if desired) to facilitate opening.
Next, modify/add geometry and arrange for cutting out of some reasonable size of stock which will fit on a machine. The largest part is 3" x 8" so we will try 4" wide boards which are a bit longer than 16" long (which will allow this to comfortably fit on any Shapeoko (my apologies to the Nomad folks).
and expand/modify geometry as necessary to allow cutting things out and to use a 1/8" endmill (the grooves for the top/bottom will be slightly increased in size to allow it to fit)
then it’s necessary to go back to the Design pane and draw up a rectangle for the stock which we wish to leave — note that since CC draws center–corner it’s easiest to draw at twice the size necessary, then reduce to 50%:
(and yes, I went through all of the over 200 boards which were in stock at my local store to find the 6 which were decently straight and left the stacks neater than they were when I arrived)
It should be feasible to change the job setup so that we clamp up three boards on effectively 10.5" wide stock and cut one box all at one go, but that’s a bit more waste stock than I can accept, so we will shorten the box a bit — the top/bottom are fine, we just have to shift the top/bottom a bit.
This file is just for .25 inch wood right. Also how do you separate such as the lid and base into separate pieces because the 16x7 file does not fit on the Shapeoko 3 which I have and not the xl?