Laser Cut Wooden Halloween Decorative Boxes with Pumpkin and Cat Designs

The lighting in my video is bad and I apologize but you will see my process. 

4x4" Halloween Box Lantern – Assembly Instructions

Designed by: David Hawke
Laser-ready material: 3 mm basswood
File source: Atomm.com

🔹 Step 1 – Download the design

1. Go to Atomm.com and download the “4 x 4 Halloween Box Lantern” file.
2. This free file includes six different designs for the same box pattern.
3. Save it to your computer or just open it directly in Xtool Creative Studio (formerly XCS).

🔹 Step 2 – Prepare your laser

1. Load 3 mm basswood onto your Xtool S1 (40 W recommended for my settings but any laser that will cut 3mm basswood will work).
2. Use your preferred engraving and cut settings for 3mm basswood.
   • Expect roughly 13–16 minutes per box depending on design.
3. Cut out all the pieces for one box.

🔹 Step 3 – Optional: Stain the pieces

You may stain the wood before assembly for added color and depth.

• Light stains bring out engraving details nicely.
• Let the pieces dry completely before gluing.

🔹 Step 4 – Organize the parts

Lay out your cut pieces:

• Four sides (with Halloween designs)
• One bottom panel
• One top lid (keep this separate; it will remain unglued)

Place engraved sides face-out and any sanded surfaces facing in.

🔹 Step 5 – Apply wood glue

1. Use regular wood glue – CA glue also works, but wood glue gives more working time.
2. Apply a thin bead of glue along the interlocking tab edges.
3. Do not glue the top tabs; leave the lid unglued so it can be removed later.

Tip: Keep a damp sponge handy to wipe away excess glue immediately.

🔹 Step 6 – Assemble the box

1. Join the sides and bottom together carefully.
2. Hold each corner snugly to ensure alignment.
3. Secure with rubber bands around the box to clamp it as the glue dries.
   • It’s normal if a little glue seeps out – wipe it off with your sponge.
4. Let dry until solid (usually 30–60 minutes).

🔹 Step 7 – Finish up

1. Remove rubber bands once the glue has dried.
2. Place the lid on top – it should fit loosely so it can be lifted off.

🔹 Step 8 – Add lighting

Use only flameless LED candles inside.

• ⚠️ Do not use real candles – this is a wood product.
• Battery-operated tealights or flicker candles from Amazon work perfectly.

🔹 Step 9 – Display or sell

You’re done! Your lantern is ready for display, craft shows, or gifting.
Each of the six included designs fits this same 4 x 4 box layout, so feel free to mix and match styles.