Computer Controlled Cutting

Introduction

In this week, we were introduced to Laser Cutting and Vinyl Cutting in addition to the softwares that are required to use the machines. By the end of the week, we were able to design our own parametric pressfit construction kit and vinyl stickers.

The List of machines and softwares that are used:

    Machines:
  1. Laser Cutting (CO2): Trotec Speedy 400 flex
  2. Laser Cutting (CO2): Universal Laser System
  3. Vinyl Cutting: Roland CAMM-1 GS-24
  4. Sticker Cutting: Roland VG-640
    Softwares:
  1. Autodesk Fusion 360
  2. Corel Draw 2017
  3. Roland Cut Studio
  4. Roland VersaWorks
  5. Laser Cutting: Universal Laser System
  6. Laser Cutting: Trotec
  7. Adobe Illustrator



Group Assignment

The group assignment is made to familiarize the members with the settings of the CO2 machines (Trotec and Universal Laser System) that are used in the lab, and can be later used for future reference while using the machine to complete the other projects. We did face a bit of trouble since during the trials, the settings didn't seem to work after confirming them last time. So we had to work with different parameters, we found out later though that the lens was cleaned which affected output. We mainly focus on Speed, Power, PPI Pulse Per Inch, Material, Depth. Those parameters change if the target is cutting or engraving, which is found out during this group assignment. After that we measured the Kerf for the material used, Kerf is defined as the width of material that is removed by a cutting process. It is measured by simply finding the difference of the theoratical dimensions (sketch done on software) and what is actually cut. The reason that it is measure is to reach accurate size by incorporating the kerf in the theoratical dimensions. More details about the group assignment is found here.



Parametric Pressfit Kit



Sketching

For the pressfit kit, i started by designing something simple so that i can build on it a certain design since i didn't have anything in mind. Also, i made sure that the design is parametric. Having a Parametric design means having the ability to change the shape of model geometry as soon as the dimension value is modified. It saves time and eliminates the need for any designer to constantly redraw a design every time one of the design’s dimensions change and thus can quickly and easily create different configurations on the design. Using Fusion 360, i defined the parameters, with reference to the kerf value for the cardboard found in the group assignemnt.The reason we need the kerf here is to incorporate it with the design and to reach the required dimension since the kerf cuts more than the required dimension which is why we measured it in the beginning.I also created a design for flexible material, a rectangular shape and a book cover, and i took the pattern from Trotec Website.After getting done with the design, underneath the sketches tab on then left, i selected my sketch and right-clicked on it to save it as DXF so that it can be used in CorelDraw to be exported directly to the laser cutting softwares.

Downloads




Cutting and Assembling

After importing the files in coreldraw, first thing is to make sure that the drawing line is hairline (red) and in case of engraving we keep it black.
  • In trotec machine, we introduce the blue color and use it along the red color for cutting in CorelDraw and that is to indicate which part will be cut first. Then we print it to TROTEC software and from there we can choose the material type and the parameters for cutting (power,speed,PPI). Before cutting the manual focus must be done which is simply by placing the piece of metal on the nozzle and raising the platform until the metal falls.Filter is automatically opened when the cutting process starts.
  • In the Universal Laser Machine, before exporting the sketch to the cutting software we choose the preferences in the print tab to specify the material and the parameters for cutting and engraving. Then we export it to the software and cut directly after specifying the start point. This machine doesn't require a manual focus but requires turning the filter on before starting.
I used the universal laser machine to cut the shapes i designed, and ofcourse i had to do several trials before reaching the correct result with my deisgn as i kept modifying the design by increasing the flexible material part. As for the parameters i used for cutting and engraving, i took the values that we tested during our group assignemnt, the picture on the right shows the tabs where the material and parameters can be changed, but the picture doesn't show the chosen parameters for cardboard since it's only for explanation purposes:
Cutting
Power Speed Frequency
80% 7% 300

Engraving
Power Speed Frequency
9% 100% 500

Vinyl Cutting

A vinyl cutter is a computer-controlled plotting device with a blade, the machine , Roland CAMM-1 GS-24, cuts vector designs that are created in a software program such as Corel Draw & Adobe Illustrator. The cutter is capable of moving the blade on an X and Y axis over the material.But,it can only cut shapes from solid colors of vinyl. Thus, a design with multiple colors must have each color cut separately and then layered on top of each other. The steps that i followed to create a sticker for my iPad is as follows:
  1. I first chose the design that i wanted to cut, which was a circuit schematic from VectorStock.
  2. Then, I opened CorelDraw and inserted the picture.
  3. Using the quick trace option, i was able to trace the picture and then turn it to white and right click on the red color to get an outline and the path for the cutter, making sure the Hairline option is chosen for the line.
  4. After that, i exported it to Roland CutStudio software by clicking on the Roland icon.
  5. The roll is then fixed to the machine.
  6. In Roland CutStudio, the width of the cutting area is modified based on the width that the machine reads. It is then ready to cut.
  7. After cutting, i removed the unwanted areas and applied an Application Tape on top to remove it safely and place it onto the surface of my iPad.
I also had the chance to try Heat Press on T-shirt, following the same exact steps mentioned above, except that the logo must be inverted so that when pressed on a shirt or other material it should be in the correct position. The Vinyl material is changed where we used heat transfer vinyl. After Cutting, the unused space must be removed by a tweezer or manually. Then I attached the sticker on top of the shirt and pressed on the machine and kept it for almost 25 seconds to ensure that the sticker is pressed well so that the transparent layer can be removed smoothly.
Downloads

Sticker

After knowing the limitations of the Vinyl Cutter, we were introduced to the sticker maker machine Roland VG-640. Unlike the vinyl cutter, Roland VG-640 can print stickers any design with different colors and then cuts the shape. The steps are as follows:
  1. I inserted the design in Adobe illustrator and then using the swatch library (to be installed) i chose the pink color to determine the cutting path for the machine, width of it to be 0.01 (hairline).
  2. The work is then exported as PDF and inserted in the Software Roland Versa Works, adding the job to Queue A.
  3. To cut the image boundary, Cut Control option is chosen.
  4. Clip & tile option is chosen to preview the work before printing.
  5. On the machine, base point must be indicated before printing to ensure that the sticker is printed on an unused area.
  6. Then in the software, we right click on the job and print, and then Sticker is ready to be used!
Downloads


Experience

This was a very interesting week since i had the chance to create things i didn't know that i could do. At the beginning, it was hard to master all the machines and softwares, but since getting to the correct result requires several trials, i got used to it and now i can say i'm familiar with those machines.