W3 Computer-Controlled Cutting

Making Puzzles

Introduction

The dream of a puzzle fan.

The puzzles in three dimensions usually follow a mathematical pattern to build it. The dream of many fan of solving puzzles is to create them easily every day.

Summary

Build something in 3D with a cutter machine

Design an object with CAD software, cut in pieces on laser cutter and assemble it on an object in three dimensions.

In order to know how it works vinyl cutter, an image (CC0) has been downloaded and cut.

Content (linked):

Assignment:
TUTORIAL LASER CUTTER CUBE PUZZLE. 

Extra:
TUTORIAL VINYL CUTTER. 
JOINTS PROJECT  

Tutorial cube puzzle. STEP BY STEP

I love puzzles, so this "press-fit construction made on laser" I wish to make a 3D puzzle. The puzzle it will be a cube which every side will be different. There is just one way to assamble the cube.

During all process, I will bring them a number to each side of the cube in order to fix all joint problems. When all joints are tested, the final cube will not have numbers engraved.

Step 1

Designing my first puzzle

Using Rhino, designing a cube which could be assembled as a puzzle. 

One of the most important aspects is the adjustment of the pieces together. 

Two layers were done: black layer that will be cut and red layer that will write without cut. Color red and black will used on laser cutter to set the tool power.

Download Rhino design with two layers here.

Step 2

Set the laser cutter properties on PC

The laser cutter is an Epilog Engraver.  All the laser cutter settings are for a 3mm paperboard. 

Those are the steps done before start to cut:

  1. Open the file in Rhino
  2. Check the are two layers (cut and write)
  3. Click Print on Rhino software
  4. Destination window/Output Type: Vector Output
  5. View and Output Scale/Scale: 1 on paper:1 in model (same units!)
  6. View and Output Scale/Set window
  7. Click M (to move the window), click space bar
  8. Move the window to set the upper corner to avoid wasting the material. Leave 1 cm between window and figure.
  9. Destination/Properties (open new window)
  10. D/P/General/Job Type: Vector
  11. D/P/Color Mapping (because there are two layers)
  12. D/P/Color Mapping/Color Mapping checked!
  13. D/P/Color Mapping/Check color and set speed and power. FOR CUT: Speed 55%, Power 45%, FOR WRITE: Speed 80%, Power: 10%
  14. After change values, click on arrow >>> to set.
  15. Order of layers on right side of the screen, set wich layer is going to be first done. For that reason, it have to be first write layer and second cut layer. If you do first cut, all pieces could move while writing process. You can change order with up and down arrows.
  16. D/P/Color Mapping/OK
  17. On the bottom right side, press PRINT

Step 3

Laser Cutter Dashboard (Spanish)

Set the laser cutter:

  1. Check the laser cutter has received the job (my job was "dado w3 v3")
  2. Open the laser cutter and fix the paperboard with paper tape. 
  3. Make sure the board is completely flat on the surface.
  4. Set the (0,0): Click on "X/Y OFF" (answer: X/Y off? GO/STOP)
  5. Click on "GO". Now you can move manually the tool to (0,0)
  6. Click on "Ajuste inicio" to set the new (0,0).
  7. Focus the tool. Click on "Enfocar"
  8. Autofocus ON? Click on "GO"
  9. Start working: "GO"

Step 4

Assembling and feedback

Now, the assembling time. The first time, it doesn't cut or fit the joints well. It was necessary to do three iterations from step 1, redisigning joints size and changing the laser cutter settings.

File with numbers. Debugging time.

Final file

Puzzle finished!! 

Notes: If you have a look on the rhino file, you will see numbers for engraving. This numbers are just for the debugging process. After everything was checked and fixed, the final version is a puzzle without numbers.

Tutorial how to use vinyl cutter. STEP BY STEP

Step 1

Get vector image

You can design your own image using CAD sofware, in that case I have downloaded a vectorial image CC0
(see alia page to know more about CC0). 

Step 2

Fab Modules Settings

Open Fab Modules in a new terminal typing "fab".
Then select image (.png) and Roland vinylcutter(.camm).
When the GUI is opened, load.png.
Make path (you will see the traces)
Make .camm

Step 3

Vinyl cutter setting

1. Prepare the cutting tool, removing it about 2mm out of the holster.

2. Introduce the vinyl paper as you would do with a printer.

3. Set the (0,0), follow instructions on the vinyl dashboard.

Send it!! on Fab Mocules and start cutting.

Step 4

Extracting and pasting vinyl 

1. Extract all the vinyl that you don't need. Do it carefully.
2. Paste with a big paper tape the whole vinyl. This tape will help us to extract the final vinyl.
3. Paste the tape with the vinyl where you want it to be.
4. Extract the big paper tape carefully and left the vinyl.

Joints Project

All kind of joints

Solving a future problem

After my experience with the cube puzzle, I realise that joints have to fit and be enough strong to make a proper assembly. For that reason I started to design all kind of joints for paperboard. The project is in progress.

Download here the actual project status