Cutting the Chassis
While Boxes.py allows setting any thickness this is really meant be be cut in 3mm plywood with the exception of servo mounts in the body (the two top most parts) which should be cut from 5mm plywood to get the right depth for the servos. Material with different but similar thickness should also work just fine. Check that the (body) servos will poke through the two layers. Always measure the actual thickness as it often differs from the nominal value. Baltic birch has worked well for us. Poppler is a bit weak but may work now as some weak points in the model have been addressed.
For the head you do not need to change any settings except the burn value. It depends on the properties of the laser cutter and material you are using. It is possible to cut the parts stiff enough that most joints do not need to be glued together. But then you may need a hammer, vice or press to get things together. If you use brittle material as acrylic this is not an option and you have to use a smaller burn value to get a more loose fit.
For the legs you have a few settings to consider. The anklebolt diameters are meant for a M3 screw that get threaded directly into the wood. If you are using a different screw size you need to adjust these two.
The default leg length is 37mm. But we found the robot to be a bit less prone to falling over with shorter legs. 34mm being the minimum - which is what we used in our workshop.
Note that you may want to add some logo at the side of the head before cutting the head. Just edit the resulting file in your vector graphics / CAD program e.g. Inkscape.
Depending on your laser cutting software it may be necessary to manually select the order of the parts cut. For the head the rectangular holes in the hinges need to be cut first. Then all the other holes and the outer border of the parts last.