After sketching out a few ideas, I decided to go with the simple and practical slotting lock, which can create great strength with a minimum of materials. A small scale model quickly demonstrated that the challenge with this design would be at the edges of the card pieces, where there is a tendency for the material to bend.I decided to try varying the sizes of the card pieces to create a rounder shape in plan view thus reducing the produding parts, and sketched out each piece to be sure that the measurements were correct and that there was sufficient material allowed to achieve the design. This led me to the next step - rounding the corners of the pieces, which reduced the likelihood of them being bent and weakening the carrying potential of the object. It also resulted in a more elegant shape.
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