Week 4:
- Computer-controlled Cutting -


Objectives:

1. Make laser cutter test part(s), varying slot dimensions using parametric functions, testing your laser kerf and cutting settings (group project).


2. Cut something on the vinyl cutter.

Design, make, and document a parametric press-fit construction kit, accounting for the laser cutter kerf, which can be assembled in multiple ways.

I will explain how I designed my objects.

I will Include my design files and photos of the finished project.


Vinyl and Laser cutting

This week I spent more than 15 hours in the lab to learn about fusion 360 and the good thing about these long staying in our lab is that my colleagues have the same passion about learning and experimenting more on the machines and software provided, which also made my journey more excited.

As a beginner in this type of labs and dealing with these sweet lovely machines ^^ I wanted to mention the lesson I learned this week too >>>> “WORK SMRTER NOT HARDER”!!! Why I am pointing that?! While the time of creating the skitch for the laser cutting assignment I did reach the result and finished my assignment.

However, I did that by following a long process, I mean, Instead of just sketching my object in 2D I did sketch in 3D shape at Fusion 360 which made me so so much confused by because of the whole elements were just in one part and I worked on the same part more than once while I supposed to work on another one!!!! That took me a long ride!

In another hand, while the previous navigation of creating 3D parametrical shape, definitely I learned more and knew more and went deeper with this amazing design software “uncle” Fusion 360 ^_*!

In previous 2 I learned how to create 2D and 3D parametrical shapes from different software suggested by the fab academy and out tutor as well and I’m so glad to learn such now designing skills which I’m sure will add more to my design and art skills

So I did create stickers from different materials and under different conditions of power to print a correct cutting of the sticker.

I created cardboard stool and table in a laser cutter.So I first sketched my design in Fusion 360 and then I saved the sketch in DXF file type after that I used Corel Draw software to print my sketch by Universal laser cutting machine.

-Vinyl cutting steps-

Im using Roland GS 240

This small screen shows the information and allows the user to change different options for the machine.

To move the blade that will cut we use the arrows to move or by pressing origin button.

So, here I chose the 60 grams force (gf) to cut the black vinyl.

Well, here I used 2 kinds of material to cut in the vinyl for the sticker, So there were one black the thin one and the golden material its kind of thick and a bit hard material, So that's why I needed to changed the power to have a nice straight line to cut.
And Also, with the gold one, I noticed that it would be better if it is for big curves not small tiny ones so you could have a sticker without any harsh moving or in another way you won't face any difficulty in removing the sticker.

So here it shows the force for the golden material which I put 150gf

- Weeding and process of transferring the vinyl cutting to the surface -

Well, here is another example and I will explain the step after the vinyl cutting process.

Applying the application tape. It is always good idea to use the application tape with the vinyl to have a professinal look and better outcome of sticker you made.

So, here is a steps I did when I used the tape:



to cut this red vinyl I chose power is 100gf

Before I remove the red vinyle I paste the application tape on the area I want to cut or remove

So this is the front side of the sticker covered with the application tape.

Next in second two pictures, I removed the corners of the sticker from my application tape except for the body as you can see I kept the letter Z but its the opposite side.

Paste the whole part on any background you want and make sure it is well pasted. Thus the Z letter will be now in the right direction.

The last step is to remove the application tape from the main part so you are getteing the sticker now.

Here I did only print the logo of "just do it" but the other golden stickers are made by our tutor at week one... We had this time creating logos with our tutor for our new laptops *.* and the room is where we all sit and work, SO there are our names and there is the logo beside my name made by me :).

Sketch

Here, is the Skitch on Fusion 360 which honestly I did learn little things about it in week 2. Sketching in this software took me the whole week !!
But I did it at the end.



In this example I learned how to apply the property of the measurement application "parametric" with my first try.

The dimensions have been applied in parametric


Kerf Testing

As a group, we managed to make several materials cutting tests and we documented the information in a table the limits by parameters like kind of material, its thickness, cutting speed, laser power minimum and maximum.

Because the laser burns away a portion of material when it cuts through. So, measuring kerf (width of a cut in woodworking) is an important thing to know in laser cutting measurements.

Kerf for sure varies according to the materials. And it also depends on the parameters in laser cutter (Speed, Power and PPI).

Well, we did a group work to measure the kerf before we start working on our own assignments, so the result will defiantly help in the measurement.


These are the tests we did as a group to decide the kerf on cardboard material.
Check the

Group assignment

Well, after testing of the measurement using a cardboard thickness of 3mm, the kerf was identified as 0.05mm

Well, after a good discussion, sitting with my professor Wendy listening to her feedback and comments on my website, documentation and work progress of my assignments from week 1 to week 6.

I had absolutely helpful and valuable comments from here especially when she’s taking me and then sudenly she move to the smart board start drawing and explaining ^___^ !...

Exactly what she did her in explaining to me about my assignment of laser cutting week.
So, what I did when I was designing my model, I just use the feature of “patterns” to create the wholes for slats, they are “13” whole and the slots shape is hex “6” thus they ain’t be able to be assembled in more than one way, unfortunately.

However, with Wendy’s explanation “physically, visually, also she took me the outside area searching for my week 4 assignment which I did by laser cutting machine but guys we are now in week 7 and my model is not there *. ^! She wanted to show me how I can modify my model and make the options more for assembling and putting parts in diverse ways and what things should be taken in account when I make my design or model.

Definitely, I wanted to apply these things and make my new small model to see the outcome, so I can show you how it looks like after all the effort she spent with me inside the lab and outside searching for my model behind each piece wood...Ta Prof. Wendy =)


So, here is the second parametric press fit of this week's goal
The change I made from previous design in the number of slots which were 13 to 12 slot and that’s to make the upper polygon part sit in any direction unlike before when the slots were 13 I could not be able to put it in more than one way only.
Change two I resized the model to half size by only clicking on scale feature in Fusion 360.
Three, The hole’s shape changed to a square so I can put the slots horizontally and vertically.

The sitting in Corel-draw, make sure the line is hairline and the vector colour is RBG-red-255

The laser sitting for cardboard is 6mm thickness as displayed in the following images. which is:
- Power: 65%
- Speed: 12
- PPI: 300

After cutting the cardboard in assembly part I discovered that because of the circle shape I can only join the circle to circle by only one joint or hole as the other holes obviously go to the opposite direction if you put them beside each other. So I did that as shown in the below image.

In future, I’ll make more of these polygon shapes so I can put them on the top of each other by joining from one join in the corner of each to make a sample like a building or big shelves




Hi again, I'm back from week 8 to you guys in week 4 just to show you my new thing I'm working on about modifying the table.

Kindly follow the link here