Table of content

• Assignment
• My Work
• Group Assignment
• Concept of Construction Kit
• Design of Construction Kit
• Measure the Model
• Sketch the Kit
• Generate SVG file from Fusion360
• Laser Cut Construction kit
• Vinyl Cut and Sand Blast
• Files
• Lessons Learned
• References

For attaching the surfaces, I decided to use the "snap" joint.

Joint from inside of polyhedron (not push out the edges as long as possible).

Multiple set of joint with different angles would allow players to make various constructional object!

For making "Pot", I need at least following joint:

• 25 pieces of 142.6 deg. joint (pentagon and triangle)
• 5 pieces of 153.4 deg. joint (pentagon and top rectangle)
• 5 pieces of 169.2 deg. joint (triangle and top rectangle)
• 10 pieces of 144 deg. joint (inner angle of regular decagon)

And more for various constructions!

At first, I applied parameters in so many places in sketch of Fusion360. However, I realized that it's not necessarily good way to set everything as a parameter. It's because 1) too many constraint increase complexity of constraints dependency. and 2) 1) causes error and unexpected behavior in model. 3) CorelDRAW, a graphic software that are used for sending cutting data to Universal Lasercutter at Fablab Kannai, has strong power that specifies the location or color settings of shapes to cut.

That's why I designed a vector lines separately for each part, then converted it into vector image in svg file. In CorrelDRAW, I checked the space and alignment for each part and finalize the cutting data.

1. sketch the joint considering cardboard thick(2.83mm) and kerf(3.5mm)

2. mirror the snap to the other side. (Actually, this the final idea of joint is not symmetry for easily attaching the joint)

3. set the joint snap ledge to 1mm.

4. set the joint snap thick to 0.5mm (Actually, this was too shallow to fixing the cardboard surface)

5. Draw center point arc as the construction line of angle.

6. Draw construction line and set the angle for pivot of mirror

7. Mirror the sketch profiles to the other side.

1. At the new sketch, create the projection line from original sketch (that is not reflected the kerf calculation).

2. In "offset" dialog, check the direction. If you want to cut outside of the shape, offset is external line. If inside, offset is internal line.

3. Reflect the offset line to the sketch.

Offset value is "a half of kerf". As I determined that the kerf for cutting cardboard in 3 mm thick is 0.35mm, the offset is set into 0.175mm

It's helpful to use offset function especially in considering kerf in complex design.

1. Tool > Shaper Utility and select "sketch profiles"

2. select the sketch profiles that you want to convert to SVG.

Occasionally, you cannot select the sketch profile especially in case of offset line. In that case, you can make body by extruding the offset sketch, check "single solid body" in 1., then you can get offset line of sketch.

3. save the SVG file directly to local storage.

Using CorelDRAW that is installed for client laptop of Universal laser cutter, I consolidated the position, alignment and spaces of shapes.

make the line for cut to ”hairline” and clear the color filled inside of the shape.

Round 1. shape of joint was weak. I changed the design of joint from "deep slit for snap for both side into "no slit and for 1 side".

Round 2. The length of rectangle was not valid because the area of sketch that I selected on "shaper utility" was incorrect.

Finally, I could measure 24.98mm in physical material cutout from design of 25.00mm!

Assembling in a different way. Multiple angles of joint supports various expression.

This is "Hand"...?

1. Open png data in Silhouette Studio

2. Panel > Trace and adjusting parameter to trace the data like "threshold" or "filter" and get clear outline.

3. Get outline data in red color.

This is the symmetric bread-man(しょくぱんマン) that I designed in Fusion360.

The bread−man（しょくぱんマン) is a very famous hero, the best friend of main charctor of Ampan-man(アンパンマン), a popular Japanese picture book. The bread-man is my 3 years-old daughter's favorite.

2. Though I used "Shaper Utility" and exported SVG file, that format (by autodesk SVG) could not be imported to Silhouette Studio directly.

So, I opened the SVG in Inkscape and export it into DXF format.

3. DXF R14 format was exported from Inkscape, then imported to Silhouette Studio successfully.

4. In design view of Silhouette Studio, I adjusted size or alignment of data for cutting.

1. For cutting the sticker, I used CAMEO by Silhouette, a vinyl cutter at Fablab Kannai.

2. Firstly, I tried to cut the sheet with sticker in "3" value of cutting pressure. However, in test cut, the sheet could not be cut out. The pressure was weak.

3(1). Set cutting pressure into "4" in software.

3(2). For adjusting the pressure, user needs to set it physically.

4. Test cut again. Cutting pressure into "4" works!

5. Completed to make the sticker!

put the coversheet for pealing off the sticker cover easily.

put the sticker and peal off the blasting area carefully using pin set

Sandblast machine is dusty... It's necessary to wear a mask.

omit the cover sheet above trash box.