How To Cut Plastic Project Boxes

Knowing how to cut plastic project boxes for electronics projects or other projects is a key step in prototyping and design. We recently completed an electronics project with a PB-3P plastic project box where we needed to mount electrical receptacles to each side of the box in order to build a smart outlet. Cutting our Plastic Project Boxes is easy with the proper planning, correct tools, and proper technique. Below are the steps on how to cut plastic project boxes effectively:

Prepare the Project Box:

1. Trace the cutting area on to a piece of paper, this will servce as cutting guide.

2. Draw a vertical line from top to bottom with a pointy object like a flat head screwdriver. This will serve as a perspective line and keep other lines stay straight. The lid plays a big role in structural integrity. 

3. When using a thin-walled plastic project box it is very crucial to install the lid before the cutting process.

Cutting the Project Box

1. Using a very small drill, 1/16″ or smaller, drill out the corners of the cuts you will be making and at any points where there is a sharp angle.

2. It is easier to cut smaller then come back to fix it. One of the easiest and most precise ways to make the cuts is with a rotary cutting tool, often referred to as a Dremel tool. When cutting with a rotary cutting wheel, place the cutting tool in the centerline then move it back and forward to finish the cut. Always use caution when using sharp tools such as these. *If you don’t have access to this type of power tool you can also drill holes at each corner of your box. You can get the Variable Speed Rotary Tool Kit from our website or your local Harbor Freight.

How to cut plastic project boxes

3. Clean up and test-fit the part. Use a filter to enlarge the hole to fit the part better if needed. Don’t be disappointed if the box breaks on your first attempt, we always recommend purchasing extra plastic project boxes in case this happens to you.

Thanks for reading about how to cut plastic project boxes. We hope you found this tutorial useful and we always welcome your feedback to improve our content. Check out our Plastic Project Box selection here for your next prototyping or manufacturing project!

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