14.Wildcard Week:

13-05-2021 | Jai Hanani

1. Objectives:

2. Assignment:

Design and produce something with a digital fabrication process (incorporating computer-aided design and manufacturing) not covered in another assignment, documenting the requirements that your assignment meets, and including everything necessary to reproduce it.

3. Files:

  1. DXF
  2. Parametric Box Without Lid
  3. Parametric Box With Lid

4. Tools

  1. Fusion 360 Sheet-Metal
  2. Zund


  1. I will be designing something using SHEET-METAL tools in Fusion 360, and cut and crease it using ZUND.
  2. I am going to make a parametric cardboard box, with lid and without lid. I will use it to carry my PCBs around.
  3. Zund G-3 L-2500:

  4. Specifications: Repeatability +/- 0.03 mm, position accuracy +/- 0.1 mm/m, working area 1800 mm x 2500 mm, high speed router 3.6kW 50,000 rpm
  5. Applications: A range of modules provide the capability to cut, score, crease and mill. Use cases include origami/kirigami for rapid cutting-and-folding of structures with tunable properties, two sided milling for press fit furniture and cutting of carbon fiber, fabric for composite lay ups.
  6. The ZUND is modular cutting system that can be adapted and used to cut, route and draw on a range of materials. With interchangeable modules, tools and blades, the ZUND can be configured to cut vinyl, fabric, leather, cardboard, foam core, rubber and many more!
  7. Software Needed: Zund Cut-Center
  8. Tools:
  9. Controls

    The console directly controls the cutter without going through the software. The console is used primarily for performing tool changes, turning the machine on/off and switching between online and offline mode. The gantry can be manually controlled by the travel keys and moved rapidly by holding the 'shift' key.

    The Vacuum can be toggled on and off by pressing the 'shift' key and 'VAC' key. Pressing any of the travel keys of 'STOP' during a cutting operation will pause the job and raise the tool until the 'Online' button is pressed, resuming the job.

  10. Light Barriers & Emergency Stop

    The Zund has safety features to prevent injury during operation. The main feature is a series of 'light barriers' that are projected from one end of the gantry to the other on the front and back side of the cutter. If these beams are broken by someone reaching into the operating area, or if a piece of stock lifts up unexpectedly, the cutter will immediately stop operation. To continue the operation after everything is cleared from the table, press 'OK' then 'Online' to continue the cut from where it stopped.

    While the light barriers are a soft stop, the red emergency stop buttons are a hard stop. When the emergency stop is pressed the operation immediately stops, cancels the current job and disengages the tools. To continue from an emergency stop the button must be twisted to be released, then follow the instructions on screen. The tools will re-engage and require initialisation and the job will need to be restarted from the PC.

    If something begins to go wrong during the cut, such as the stock moves unexpectedly, the operation can be paused by pressing any of the grey directional buttons on the console or 'online'. The job can then be resumed by pressing 'online' once the issue is resolved.

  11. Navigating Cut Center:

  12. Operation Parameters within Cut Center:

  13. Design:

    I am designing a parametric packaging box made with cardboard. I want to make 2 version, with a top-lid and without a top-lid.

  14. Open Sheet-Metal in Fusion 360
  15. Click on Modify > Sheet-Metal Rules
  16. Create a new rule by clicking on the "add" symbol.
  17. K-Factor: Image result for what is the k factor in sheet metal K factor is a ratio between the distance from the neutral bend line to the inside bend radius and the material thickness.
  18. Since I am going to crease cardboard, to approximate that, I am going to put k-factor to '0'.
  19. Bend Conditions:
  20. Bend radius should be close to '0' to approximate cardboard creasing.
  21. Corner Conditions:
  22. Parameters:
  23. Make a rectangle with "length" and "width" parameters.
  24. We will be using Create > Flange a lot.
  25. Click on Flange, and Click on the rectangle. It will extrude itself.
  26. Click on Flange, and Click on two edges, and put-in the Height as "height"
  27. Go here. To understand more about 'Height Datum' and 'Bend Position' options.
  28. Take the top-edge of one side, and flange it out. Height should be atleast 2 * Thickness.
  29. Draw 2 rectangles equidistant from each other with length "length/5" and width "thickness + 0.20". Those rectangles should be in 7.8mm distance from the side[This 7.8mm comes from previous step. ]
  30. Extrude those rectangles down.
  31. Take the edge shown in the figure, and flange it to the bottom. Do not flange completely to the bottom. We never want to join things in sheet-metal.
  32. Flange on of the rectangles like so: Remember to keep 0.20mm offset from either side, for a good fit.
  33. Do the same with other rectangle:
  34. Mirror everything to the other side.
  35. Pick a frontal edge, and flange it to the top:
  36. Pick one-side of the previously flanged edge, and pull it inside into the slot. Like so: Do the same to the other side.
  37. Mirror all these to the back:
  38. Pick the top-edge from the back, and flange it all the way to the front face.
  39. Pull-it down, like so:
  40. Flange that edge, till the start of the slot:
  41. Take that inner edge, and pull it inside the slot:
  42. Using unfold pattern, unfold that particular flap. Filled it. Fold it back.
  43. Flange that edge down to the bottom.
  44. Mirror it.
  45. Unfolded. This means, everything's well.
  46. Fillet the edges.
  47. Make an extrusion there, for good sealing of the box.
  48. Flange that edge in.
  49. Fillet that face.
  50. Parametricity:

  51. Parametricity, without Lid:

  52. Final DXF:

  53. Fabrication:

    Since, this is a very costly machine. Bulk of this process is done by my instructor. I will write down what I remember.

  54. Product:

    Putting it to use: