Completion time: 4 hours
Airplac Creative Kit:
4 Airplac Premier 5 mm
3 Airplac Black 5 mm
1 Airplac Kraft 5 mm
1 Airplac CORE 5 mm
1 Airplac Graphic 3 mm
2 TAC self-adhesive sheets
Other tools and accessories:
1 cutting mat
1 precision cutter (start the project with a fresh blade)
Spare cutter blades
1 metal ruler
1 pencil
1 eraser
Black markers in various thicknesses (1 mm, 3 mm)
Prerequisites for completing the project:
Patience
Focus
A clear, uncluttered workspace
Artist Ad-Rien invites you to create a miniature world using foam board. This relatively complex project is intended for people who are comfortable cutting with a craft knife and assembling precise components. However, to keep it accessible to as many people as possible—and to encourage you to dive in without adding unnecessary difficulty—Ad-Rien has designed three levels of creations.
Here is Level 3: the most advanced one.
The display comes to life thanks to a system of gears that makes the fox move. The gear mechanism can be adapted to various scenes and characters for those who are more skilled.
You can also discover Level 1 and Level 2.
The first part of the tutorial consists of transferring the templates onto the different foam-board sheets.
Download and print the templates on thick paper (at least 90 gsm) to make tracing the outlines easier.
Cut out the printed templates.
Be sure to cut inside the template line to keep the dimensions accurate.
Using a ruler is recommended for straight geometric shapes.
Using a ruler is recommended for straight geometric shapes.
Fill an entire foam-board sheet before starting the cutting process.
Tracing tips on foam board:
Position your templates in the corners of the foam-board sheets to obtain clean right angles, which will make assembly easier later on.
The tracing doesn’t need to be perfect for organic shapes like mountains—slight imperfections can create interesting contours.
You can erase pencil lines after tracing if needed.
For the box, take measurements and use a ruler instead of the templates, as you will need a full sheet of black foam board.
Drawing on the elements (optional)
Before moving on to cutting, it’s best to complete all the drawing work, as it will be more difficult (though not impossible) to draw on the pieces once they are cut out.
It is recommended to use black markers with 1 mm and 3 mm tips for the illustrations.
You can follow the illustrations provided with the templates, or create your own entirely different designs.
Cutting
Once all the pieces have been traced and illustrated, you can move on to cutting them out. There are more or fewer pieces to cut depending on the level you’ve chosen. Here are the techniques and tips that will help you achieve clean, precise cuts.
Important notes about cutting:
For your first time using the material, it’s helpful to get familiar with different cutting techniques. Don’t hesitate to draw shapes on a sheet of AIRPLAC PREMIER WHITE 5 mm to practice various cuts (straight lines, curves, angles, etc.).
Caution:
Black foam board (AIRPLAC BLACK 5 mm) is limited in quantity, so make sure you’re confident before you begin working with it.
Important for this level:
For the box components and the mechanical parts, precise cutting is essential for the success of the project. Using the templates, combined with accurate tracing techniques, will ensure properly sized pieces and make the final assembly much easier.
Foam-board cutting tips
Always position the cutter blade outside the shape you are cutting to avoid slipping into the important area.
For straight geometric shapes, use a ruler to ensure perfectly straight cuts—even if you already traced the lines using the template.
If the blade becomes dull, don’t hesitate to replace it to avoid tearing or damaging the pieces.
Keep all foam-board scraps produced during cutting. They will be useful later for creating supports during the scenery assembly stage—and can also come in handy for future projects.
Techniques for cutting rounded shapes
A multi-step cutting method is recommended:
start with a rough cut, then make several successive cuts to gradually refine and smooth the shape.
See the video on foam-board cutting techniques corresponding to this step
For the moon, cut the circle using small, gradual cuts with the cutter blade held perfectly vertical. Go over the circle repeatedly, pressing the blade deeper each time until it goes through the full thickness of the foam board.
See the video on foam-board cutting techniques corresponding to this step
Technique for cutting obtuse angles:
For shapes like the fir trees, first make a rough cut of the overall silhouette.
Then trim each angle by cutting from the center toward the outside of the shape, crossing the cutting lines. This approach helps achieve clean, sharp angles without tearing the foam board.
See the video on foam-board cutting techniques corresponding to this step.
Cutting and texturing the clouds
You can use the back of the craft knife or a pencil to texture the clouds, gently pressing to create slight bumps and a subtle relief effect.
Cutting the cloud shapes with a slight angle can also add texture.
The natural texture of foam core is an advantage for this type of shape.
See the video on foam-board cutting techniques corresponding to this step.
Half-cutting technique (used only for constructing the box)
The first step is to make several light passes with the cutter, without pressing too hard, so as not to cut through the second layer of foam board.
Next, place a piece of foam board under the part you are cutting to raise it slightly. Hold the cutter parallel to the table and cut along the edge of the piece. You can make several passes to ensure a clean cut.
The final step is to scrape off the excess foam with the cutter blade.
See the video on foam-board cutting techniques corresponding to this step.
Through-cutting technique:
For cuts that need to go all the way through, place a piece of foam board under the part you’re cutting to make perforation easier and cleaner.
See the video on foam-board cutting techniques corresponding to this step.
Cutting the notched mechanism:
For the wheel teeth, start by roughly cutting out the general outline of the wheel.
Then finish each notch by holding the cutter blade perfectly vertical, with the cutting edge facing the traced line. This ensures clean, precise notches.
See the cutting-technique video corresponding to this step.
Checking and assembling the elements
Before starting the assembly, use the printed templates to verify that all the pieces have been cut correctly.
Assembling the base and back panel
The method is the same for all three levels. Only the top and front parts of the base differ in Level 3, as they include notches for the gears.
Glue the two side pieces along three edges (do not apply glue to the edge that will rest on the ground).
Attach these sides to the bottom of the back rectangle.
Glue the back edge of the base’s top piece, then attach it above the two sides.
Glue the top edge of the front panel and attach it to the front to close the base.
Assembling the mechanism
This is the most technical part. All pieces must be cut to the exact dimensions for the mechanism to work properly. Don’t worry if some pieces turn out too big or too small—you can always adjust or remake them. Make sure to fully test the entire setup before gluing any parts together to avoid having to redo everything because of a single faulty piece.
Extra tip:
In case of mistakes, white foam board can be used instead of black to create replacement gear parts.
Assemble the pieces one by one: apply glue using the TAC adhesive sheet, then stack and bond the elements together.
Glue the entire mB piece, then attach it onto the mA piece.
Place piece mD—without gluing it—into the mA + mB assembly.
Insert the mK axle into the mM gear wheel, then place the entire unit into the mechanism section that was previously assembled.
Apply glue to only 0.5 mm on each side of the underside of piece mC (be careful not to glue the entire piece—otherwise the mechanism will be completely blocked).
Then glue piece mC onto piece mB.
Apply glue, then attach piece mG to the top of piece mD.
Apply glue, then attach piece mJ to the upper left area of mB.
Apply glue, then attach piece mE onto the mC + mJ assembly.
Glue the two mF pieces together, then attach them to the right end of mG.
Next, glue mH onto mI, then attach the entire assembly onto mF.
Glue piece mO vertically onto the upper right section of the mechanism.
Then, in the same way, glue the three mP pieces onto the three remaining edges of the mechanism.
These will serve as spacers once the mechanism is inserted into the base.
Apply glue to the back of the fox base (mN), then attach it onto the mH + mI assembly.
Once the mechanism is assembled, check that everything works properly by inserting it into the base.
Make sure to position the fox mid-stroke on the mechanism so that it can pass through the slot where it moves.
Once everything is working correctly, remove the mechanism and proceed to the next step.
Assembling the scenery
First, cut small pieces of foam board that will serve as spacers to place between certain layers.
The order of the layers is numbered on the first page of the templates.
Important: Layers 2, 7, and 8 are empty.
The assembly order matters. Refer to the following steps.
Assembly – Step 1:
Begin with the kraft mountain (layer no. 3).
Glue three small spacers, each made of two layers of foam board.
Next, apply TAC adhesive to the bottom of the mountain and to the three spacers, then attach the entire assembly to the back panel and the support.
Assembly – Step 2:
Glue the white mountain (layer no. 4) directly onto the kraft mountain (layer no. 3).
Assembly – Step 3:
It is best to pre-assemble the elements from layers no. 5 and no. 6 at the same time.
You will need:
Two spacer thicknesses on the mountain:
one 5 mm spacer
one 3 mm Air Graphic spacer
Two 5 mm spacers on the castle.
These spacers will ensure the correct depth and alignment before gluing the layers in place.
Assembly – Step 4:
Use the layout diagram of the elements to help verify their positions and assemble the pieces correctly.
Assembly – Steps 5 and 6:
Assemble the mountains and illustrated trees in the same way as in Level 1,
but without the black fox and without the illustrated fox, which will be added in motion during Step 7.
Assembly – Step 7:
Insert the mechanism into the scenery.
Make sure to position the fox mid-stroke on the mechanism so it can pass through the slot where it moves.
Assembling the box:
First, apply adhesive to the edges of the two side panels, as well as 0.5 mm along one of their sides (tip: use the edges of the TAC sheet for this).
Attach these sides to the back of the box, aligning them with the half-cut edges.
Repeat the same process with the top panel of the box:
apply glue to three edges (the sides and the back), plus 0.5 mm along the three sides.
Once everything is assembled, check that the scenery fits properly inside the box by sliding it in. Then remove it.
⚠️ Important:
If the inside of the box will be lit, the following steps must be completed after Step 8: “Lighting installation.”
Next, apply glue to the entire front panel.
Reinsert the scenery, then attach the front face of the box.
Lighting installation:
This final part covers the installation of the lighting (if this option was chosen for Level 2).
The first step is to make a small hole using a pencil on the left side of the support, at the level of the foremost black mountain, so that the light string can pass through.
Next, pass the entire light string through, keeping the battery pack hidden underneath the support.
Using a hot glue gun, attach the light string at several points distributed along the entire inner perimeter of the frame.
Be careful to position the lights 0.5 mm from the edge all the way around so the front panel of the box can be inserted at the end.
In the upper corners, create a small cluster of LEDs (about three).
Try to position all the LEDs symmetrically on both sides of the box.
Once this step is complete, reinstall the mechanism with the fox beneath the base for Level 3.
Showcase completed — Level 3
Did you enjoy this project and want to create difficulty Levels 1 and 2 of this model?
Visit the Tutorials page!
