This project is a good introduction to using 123D Make. 123D Make is a software that will allow you to turn any stl file into puzzle like cardboard slices. I have included a zip file with all the pdf, stl and 3dmk files for this project.
Step 1: Tools and Materials
Step 2: Using 123D Make
First download and extract the zip file. The default size is for a 29 cm long shuttle. If you want to change the size, launch 123D Make and open Body.3dmk. Type the desired dimensions in the object size box. Then open all the other .3dmk files and increase all the other object sizes by the same amount. After that click the "get plans" button and select file type, then click Export.
Step 3: Cutting
If you are using a laser cutter set it so that it cuts through on the blue lines and just etches the red lines. If you are hand cutting, print out the pdf and glue them to cardboard, then cut them out with the Xacto Knife.
Step 4: Gluing
First, assemble all the layers of the main body. Now put layer 3 on the plywood and hammer 6-10 nails around it to use as guide. Apply glue to the bottom of layer 4 and using the guides put it on top of layer 3. Repeat this step until layer 20. Afterwords put a weight on it and leave it to dry. Glue together the tanks using the same procedure. While it is drying, glue the wings, layers 1 and 2 , together. When they are both dry, glue them together by lining up the body with the guide lines on the wing. Next, insert the rudder into the slot at the back of the body and glue. Finally, glue the nozzles together, following the assembly directions in 123D Make.
Step 5: Assemble
First apply glue to the back side ridges beneath the rudder, then glue he tanks on. Next add glue to the end of the nozzles and attache them on in a triangular pattern. Now your shuttle is ready to paint!