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Fab Academy 2019 Berytech Fab Lab

Week 4: Computer-Controlled Cutting

During the fourth session dated February 6 2019 of the "Fab Academy Program 2019" we were introduced to the Vinyl and Laser cutters. The objective was to learn how to use these machines.
Our Group assignment is to characterize our laser cutter(model, functionality), and make test part(s) that vary cutting settings and dimensions (find the kerf of the materials).
And as individual assignment we should cut something on the vinyl cutter and document it and design, make and document a parametric press-fit construction kit, accounting for the laser cutter kerf, which can be assembled in multiple ways.
There are many different technologies available in the market that are used to cut into various material, and that are computer controlled. Among those computers controlled cutting technologies are the Vinyl Cutters and the Laser Cutter.

Characterize our Laser Cutter EPILOG FUSION M2:
Laser Cutting is a non-contact process which utilizes a laser to cut materials, resulting in high quality, dimensionally accurate cuts. It is typically used for industrial manufacturing applications, but is also starting to be used by schools, small businesses, and hobbyists. The process works by directing the laser beam through a nozzle to the work piece. A combination of heat and pressure creates the cutting action. The material melts, burns, vaporizes, or is blown away by a jet of gas, leaving an edge with a high-quality surface finish.

    We are using the EPILOG FUSION M2 with the below specifications:
  1. 120 Watt,
  2. Working dimensions:812 x 508 mm,
  3. Maximum Material Thickness: 101.5 mm,
  4. Manual Focus,
  5. Red Dot Pointer,
  6. CO2 based,
  7. File type:AutoCad, JPG, and BMP for raster,
  8. Operating Modes: Optimized raster, vector or combined modes with engraving and cutting in one job,
  9. Laser System Classification: Class 2 Laser Product-1 mW CW Maximum 600-700 nm,


The materials and their according power, speed and frequency are listed in the below tables:


Available Material:
3mm MDF which happened to be of 3.17 mm after measuring it accurately with the caliper. For cutting the wood, the power of the laser cutter should always be 100; the speed varies according to the thickness as mentioned in the above table. We calculated the kerf of our laser cutter via two types of tests.

First test:
Objective: Select the best cutting setting in terms of speed, power, and frequency. In our case, for wood, power and frequency are known. Cutting speed needs to be determined
Method: Cut multiple lines with different speed settings around the reference speed provided by the manufacturer's specifications. Observe by eye at which speed the material is fully cut. The first fully cut line should be the thinner cut, thus the smaller kerf.

Second test:
Objective: Measure the kerf for the setting previously selected.
Method: Cut one or multiple segments with the same setting. Measure the length of the outer frame, measure the length of the adjacent cut segments, divide the difference by the number of cuts. The result is an estimation of the kerf. We made two tests with different layouts to get an average.

How to perform the tests:

    First: Drawing a test layout.
  1. Draw a layout on a vector type CAD (we used AutoCAD). Make sure there is no line superposition to avoid cutting the same line twice. The lines should be cut in a single cut with same parameter should be joined into one line. (Click "Ctrl + A" then "Join"),
  2. Save as DXF 2007,
  3. Import DXF file in Corel Draw. Make sure all the lines are hairline (hairline will be cut; other lines will be engraved). Place the drawing in top left corner,
  4. Open the laser cutter properties window (Ctrl + P for printing the job). In the general tab select vector job type, in the layout tab select top left corner for positioning, enter machine bed dimensions (800x500 mm for our machine),

    Second: Color mapping (for Test 1 only):
  1. Color mapping helps in feeding different settings for each different line, so that the laser cutter understands that it should not cut all the lines in the same way or speed,
  2. In Corel Draw, color each line with a different color and note the RGB of each color,
  3. In the laser cuter properties window, open the color mapping tab, copy the RGB previously noted and assign cutting parameters for each color, specifying speed, power, and frequency (in %),
  4. For wood, the power will remain at 100%, and the frequency at 10% according to the manufacturers specifications. So in this case only the speed will vary,
  5. According to manufacturers specification, the reference speed value for wood is 40%. So the speed setting will have to range around this value,
  6. Select vector and deselect raster to cut and not engrave (it should not make a difference if all the lines are hairlines),



    Third: Operating the laser cutter and applying safety rules and regulations:
  1. Turn on the machine; load the file to the laser cutter by clicking print. The work now is on the laser cutter interface,
  2. Position the wood board on the laser cutter metal bed. Then place the gage tool to calibrate the focal point of the laser on the right Z value. When the gage touches the board, zero Z. Then move the laser cutter head to the starting position and zero XY,
  3. Before starting, make sure that the compressor is turned on, as well as the extractor, to enable air flow to evacuate the fumes and prevent fire risks and toxic fumes inhalations,
  4. Start cutting, and supervise the machine till the job is completed (the laser cutter should not be left without supervision while operating),
  5. Once the job is done, wait for fumes to be fully evacuated before removing the board,


Test Results:

First test: The best cut appears to be between 28 and 30% speed.

Second test:

    Evaluation of the kerf for speed 29%:
  1. Test 2A: Kerf = (33.45-33.27) / 2 = 0.090 mm
  2. Test 2B: Kerf = (100.28-99.25) / 11 = 0.094 mm


    Evaluation of the kerf for speed 30%:
  1. Test 2A: Kerf = (33.81 - 33.73) / 2 = 0.04 mm
  2. Test 2B: Kerf = (100.34 - 99.88) / 11 = 0.042 mm


Cutting on the Vinyl Cutter:

Vinyl cutters are computer controlled machines, which resemble to mini printers. The cutting machine uses a sharp computer controlled blade, which is used to cut small shapes and letters from sheets of colored vinyl. This way, labels and symbols are made from vinyl cutters. The entire operation is very simple, because shapes are cut out from vinyl, which can then be stuck on any surface.

Powered by a digitally controlled servo system, the Puma III produces eye-catching graphics with up to 23.62 ips (600mm/sec) cutting speed, 400g of cutting force, and five meters (16.4 feet) of tracking ability.



    Vinyl Cutting Process:
  1. Design in any software of your choice,
  2. When your design is ready export as .dxf,
  3. Open CorelDraw and insert your .dxf file,
  4. Make sure for the width of the lines to choose "hairline" for all the vectors that you want to cut,
  5. Print using a layout of "top left corner",
  6. Cut out the printed part,
  7. Weeding: Remove unwanted material and attach the sticker to a transparent adhesive to be able to transfer it to the wanted surface,
  8. Clean the surface you want to attach your sticker with alcohol and place it carefully while detaching the sticky adhesive,

I started designing my logo to be cut on the vinyl cutter having in purpose of using it later on as a logo for my final project. I started by drawing a rectangle of 125 x 105 mm, then two circles having 137.5 and 200 mm as diameter. I trimmed the edges and fillet the corners with 4 mm diameter.

After that I used the insert .dxf function to insert the text file "Dehumidifier" and locate it. At the end I saved the file as .dxf in preparation to cut it on the vinyl cutter by using the CorelDraw software.

After cutting my logo on the vinyl cutter I gently removed the unnecessary materials.


Design and make a parametric press-fit construction kit, which can be assembled in multiple ways:

I draw the parametric design using the Autodesk FUSION 360 taking into consideration the laser cutter kerf.
Since the available material in the market is 3.17mm not 3mm. So the additional removed kurf (0.09mm) mentioned above will totally fit with the available material. In the below test i tried different width senarios.



I started to draw a rectangle and enter L1 as distance, then a second rectangle with g1(10mm) and g2(3)mm. Then I created a center-point by using create point function and mid-point on one the side of the rectangle and the 50 x 50 mm square.


Then I used the Midpoint of the Constraints to relocate the rectangle to the left side wall of my square. After that I draw a 50mm circle using sketch shortcut and "Center Diameter Circle C" and by hitting Diameter (to use the parameters value).


Then I used the circular pattern to draw the 7 remaining grooves. I selected the 3 lines of the groove then I selected the center of my circle as a reference to rotate and draw the remaining grooves. Then I stop my sketch and hit the extrude button and selected the black wireframe and defined 3mm as depth.

After finalizing I enjoyed the parametric function by changing the groove depth and width as you can see in the below pictures.


I continued the drawing of my two remaining models: hexagon and the square one. I enjoyed the parametric function by changing the groove depth and width as you can see in the below pictures.







Since the press fit process can be better understood with the cardboard, I will redo my model using cardboard. In order to make the assembly process easier, I added some chamfers to the slots.



Download files:

Logo Design in DXF format
Logo Design in Fusion 360

Parametric Design 1 in DXF format
Parametric Design 2 in DXF Format
Parametric Design 3 in DXF Format

Parametric Design 1 in Fusion 360
Parametric Design 2 in Fusion 360
Parametric Design 3 in Fusion 360

Link in DXF format
Cardboard Design 2 in DXF format
Cardboard Design 3 in DXF format


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