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How We Physically Make A Sample Box
Following on from last week’s blog, we thought we’d share the next stages of our sample box’s journey. We recommend that if you haven't already, check out our latest blog before continuing. After the Research and Design phases, the process moves on to Testing-
Testing
Testing begins by placing a single standardised sheet in Betty (our laser cutter). This is usually an offcut from previous cuts to save wood, and limit waste. The sample takes about 1-2 minutes to complete, and does not feature any etchings or designs, saving time and resources. The sheet is then removed and assembled according to Brad’s design.
At Craft Crate we take great care with our tests and only release products that are as close to perfect as we can create. If all the pieces fit tightly together during assemblage, and the overall design is flawless, mass production can begin. However, more often than not, minor tweaks are required to meet our quality standards. The balance of an activity may be slightly off, or the grooves of a piece slightly too wide. Alterations are made via CAD (computer-aided design) software.
We run another test with the alterations, and repeat this process of tweaking and cutting until we are satisfied with the result. This rigorous testing process ensures we provide the highest quality to our customers. It also ensures children are given products that are challenging enough to keep them interested in the activity, but not disconcerted by the more difficult designs.
Production
Production is actually the easiest stage. Once a design passes the testing phase, we begin to produce items on a much bigger scale. Sheets of sustainably sourced radiata pine (1200mm x 800mm) are placed inside Betty and the designs are cut into each sheet according to the software selected on our computer. Brad is able to make as many copies as necessary, and replaces each sheet once it is finished.
Each file Brad selects has areas that require cutting, and areas that require etching. This helps create an authentic design that our children love to play with. The laser cutter works slightly differently during each of these stages.
In order to cut through the sheet, the wood is vaporised by the laser, but in order to etch patterns and marks, the power is lessened to only burn the wood. A full cut can take up to an hour but this varies depending on the design and details. This process is repeated until all orders are cut and ready for launch.
Launch
Each term we launch a new range of products in our sample box, FREE to all centres that sign up. We advertise our products on our Facebook page, Instagram, Pinterest, and email list.
We are lucky enough to be able to say we send our sample boxes Australia-wide, with customers in every state and territory. We have come an extremely long way since our first sample boxes were sent out to just our local community, and would like to take this opportunity to thank all of you for your continued support.
We consider you our friends and neighbours and hope to continue this wonderful relationship. Our latest sample boxes are being sent out in Week 2, Term 4. This is slightly earlier than usual, to ensure everyone has enough time to plan for the Summer Holidays.
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