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I used the SculpFun S9 90W laser cutter for this project. Please note that cutting parameters may vary depending on the type of cardboard used, but for this project, I used the following settings:

Cutting: 900mm/min at 90% power.

Engraving: 2400mm/min at 40% power.

The DXF files were created based on the measurements of the original ASUS GA401 laptop, with the exception of the screen, which is thinner than two layers of cardboard. You can adjust the thickness of the cardboard used for the frame to achieve a thinner result if desired. The keyboard design was sourced from a generic vector I found on Freepik.

The hinge is done with a simple rectangular bended piece of carboard, but you can use other method if you like.

Warning: I put the hinge on the base dxf file to optimize the space, you must cut it just once, because you just need one hinge, but you must do 3 pieces of the base, you must delete the rectangular shape from the cutting when cutting the second base.

Here's what you need to do:

Conduct tests to determine the optimal cutting and engraving parameters for your specific cardboard material. Each sample may have different properties, but samples from the same cardboard box should have similar characteristics.
Load the DXF files into your laser cutting software. I personally used Lightburn (the LBRN2 file is also attached), but you can use LaserGRBL if you prefer.
The last component is the keyboard. Import the AI, PDF, or DXF file that works best with your cutting software. If you're using Lightburn, you can open the LBRN2 file instead. In your cutting software, ensure that you distinguish between cutting and engraving. The PDF, AI, and DXF files have the outlines and letters on separate layers, but your cutting software may not recognize this. Therefore, you'll need to manually import them separately. The LBRN2 file already has this separation. I engraved all the keyboard layout because i was having problems with the keys and the air assist, but try to cut the keys separately for better result.
Once you have all the pieces cut, assemble them together as shown in the picture, and you're done.

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GA401 ASUS Cardboard

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