Definitely post it!
I designed this from scratch but it's very simple
use this website to help make boxes. https://en.makercase.com/#/
You just put in the dimensions you want and it spits out the cut file. Once you have that you can just add your button placements in whatever software you use.
Regarding power consumption I found this on the Trotec laser website. In the example they provide they are working with an 80watt laser so cut that in half for the K40. They are a commercial laser company so they are also assuming you are cutting every day.
https://www.troteclaser.com/en-us/learn-support/faqs/laser-power-consumption
In order to give you a specific figure for power consumption, we have drafted the following example:
A Speedy 400 laser machine with 80 watts laser power An average effective working time of 2 hours a day Of which 50% of the time with maximum laser power (80 > watts) and 50% of the time with half laser power (40 watts) This results in a power consumption of approx. 50 kWh per month, which corresponds to the consumption of 2 office PCs. This is always a surprisingly low value for many customers.
Looks like a nice gift!
I don't think it actually pulls too much current, compared to other power tools. It's powered off 115v, amps aren't super high. Less than most of my tools.
I have not used blender or a 3d printer but I would guess it's probably a lot easier to design since it's 2d. There is a little more planning maybe because you have to visual how the 2d plans will come together in real life.
I think you would have no problem if you are already doing 3d printing
This is the way! I made a diy one that works well for my dust collector.
Nice thing about a laser cutter is the speed. They are much faster than a 3d printer for templates.
I started with K40 Whisperer, then after about a year I swapped out the control board and use Lightburn now.
I use inkcape usually for the initial designs.
Yep, I've done some router templates. And used it to help make accurate interior dimensions for boxes
Yep I cut up to 1/4 inch ply, but mostly I do 1/8th inch.
There is hope for the future.
The seems like a good candidate for a series of images.