Plan A was to use acetone to bond the parts of the robot’s laser-cut casing together. However, the overarching goal is to make a kit that can be sold to kids, and it occurs to me that having ‘Buy acetone’ as the first step isn’t going to increase the popularity of the kit with kids or their parents.
Plan B therefore is to join the perpendicular sides with bolts, which require only a screw driver. I think I’ve come up with a way to do this. Here’s how a corner would look:
Here’s the exploded view of the pieces (bolt and nut threads not shown):
And here are the pieces laid out:
I hope I can get away with just four bolts, one in each corner on the bottom. Meanwhile, the top is just going to be a lid and the front and back will be locked into place with tabs and slots into the other sides.
I’ll look into that design configuration tomorrow.