Letterforms were generated on acrylic stock and made into cards that drop into a slot on the front of the box. The VersaLaser was used to ensure uniformity, but also made the process much quicker.

The box itself was constructed of half inch clear acrylic stock and machined entirely in the shop.

A clear tube in the center allows children to view the entire
extrusion process. Students were able to utilize a full range
of shop skills. While most of the machining was done on a
band saw and manual mill, the plunger was finished on the
lathe.

The box in its completed form can extrude any letter of the
alphabet. It teaches children about the process of extrusion
and also the limitations. Some letters, such as M, E, S, and T
extrude very nicely, but the centers remain in letters with
negative spaces, like A, B, R, and Q. The project was well received by young children, grown-ups, and even peers.