Paper crafts
Explosion-box card prototype
Four loose 45 mm side panels fold around a 60 mm center, with a separately sized lift-off lid.
US Letter · 4 PDF pages · Print PDF
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- US Letter
- Pages
- 4
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Print the matching Letter/A4 edition at actual size (100%). Measure the 50 mm bar before cutting; trial-fit the parts with your chosen material.
See what is on each page
- Page 1 — Assembly instructions
- Page 2 — 60 mm center with four 45 mm side panels
- Page 3 — Separate lift-off lid complete cut boundary
- Page 4 — Assembly instructions
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Explosion-box card prototype / LETTER
Revision history and earlier files
Revised editions available
Reduced parts overview - not a cutting sheet; bounded original-geometry guidance correction.
Exploding Side Panels gift box project / LETTER - guidance revised; Exploding Side Panels gift box project / A4 - guidance revised
Earlier files remain in the edition choices. Saved Print Tray recipes keep their exact original files.
Every earlier exact file link remains available in the complete file list.
A good fit for your idea?
Letter and A4 preserve the component dimensions. Choose the sheet you will print, not a different object size.
Materials and construction
Plain 100 to 140 gsm paper for a first dimensional trial; approximately 160 to 220 gsm card only after confirming the folds. Use a ruler, suitable scissors, a blunt scoring tool and a small amount of paper adhesive. An adult should handle internal cuts, holes and small fasteners.
Before making a batch
Measure the 50 mm reference and two named component dimensions.
Make a complete empty trial and document fold direction, joining order, collision, stability and any fragile features.
Repeat the trial using your chosen paper. Check that every join holds and each moving part works freely before decorating.
Printing, file details and help
About this file
- Instruction pages
- 2
- Orientation
- Portrait
60 x 60 mm center; four 45 mm loose side panels; lid face 61.6 x 61.6 mm.
From file to finished page
- Cut the cross-shaped base and fold all four sides upright without joining the corners.
- Assemble the separate shallow lid by gluing its corner tabs behind adjacent walls.
- Place the lid over the four raised sides; test clearance without forcing it.
- Lift the lid to let the side panels fall open. Decorate panels separately so no hinge is bridged.
Printing and use notes
Drawing dimensions describe flat paper surfaces, not verified internal capacity, load strength, fit or material compatibility.
No mailing, food-contact, archival, toy-safety, protective-wear or cutting-machine certification is supplied.
Make a plain-paper trial first; paper thickness and fold accuracy can change the fit.
Direct PDF files by design
Explosion-box card prototype (2 files)
- US Letter — print PDF · 4 pages
Page numbers and contents
- Page 1 — Assembly instructions
- Page 2 — 60 mm center with four 45 mm side panels
- Page 3 — Separate lift-off lid complete cut boundary
- Page 4 — Assembly instructions
- A4 — print PDF · 4 pages
Page numbers and contents
- Page 1 — Assembly instructions
- Page 2 — 60 mm center with four 45 mm side panels
- Page 3 — Separate lift-off lid complete cut boundary
- Page 4 — Assembly instructions
Exploding Side Panels gift box project (4 files)
- US Letter — print PDF · 5 pages
Page numbers and contents
- Page 1 — Assembly instructions
- Page 2 — 60 mm center with four 45 mm side panels
- Page 3 — Separate lift-off lid complete cut boundary
- Page 4 — 42 x 36 mm side-message panel (4 pieces)
- Page 5 — Assembly instructions
- A4 — print PDF · 5 pages
Page numbers and contents
- Page 1 — Assembly instructions
- Page 2 — 60 mm center with four 45 mm side panels
- Page 3 — Separate lift-off lid complete cut boundary
- Page 4 — 42 x 36 mm side-message panel (4 pieces)
- Page 5 — Assembly instructions
- US Letter — print PDF · 5 pages
Page numbers and contents
- Page 1 — Reduced parts overview - not a cutting sheet
- Page 2 — Base - page 2
- Page 3 — Lid - page 3
- Page 4 — Message panels - page 4
- Page 5 — Assembly instructions - page 5
- A4 — print PDF · 5 pages
Page numbers and contents
- Page 1 — Reduced parts overview - not a cutting sheet
- Page 2 — Base - page 2
- Page 3 — Lid - page 3
- Page 4 — Message panels - page 4
- Page 5 — Assembly instructions - page 5