Week 03

During the Fab Lab safety training, the risks associated with the use of the laser cutter and vinyl cutter were identified.

The importance of the following was understood:

• Constantly monitor the cutting process
• Do not leave the machine running unattended
• Correctly use the permitted materials
• Properly configure parameters before cutting

This training allowed the equipment to be operated safely and responsibly, reducing risks and ensuring quality results.

2. 2D Parametric Design (Construction Kit)

For the design of the construction kit, Corel Draw was used using units in millimeters, which made it possible to define precise measurements for the laser cutting.

The thickness of the material (3 mm)was established as the main variable, from which the slot slots were sized. These grooves were designed with a slightly lower thickness adjustment in mind, in order to compensate for the laser kerf and achieve a firm assembly.

The design was built from basic geometric shapes (squares, circles and pieces with grooves), which were duplicated and organized to generate a modular system. The parts can be assembled in different positions, allowing multiple configurations without the need for adhesives.

To facilitate the adaptability of the design, the dimensions can be modified proportionally, allowing the kit to be adjusted to other material thicknesses or structure sizes.

DESIGN PARAMETERS

Define this in Fusion → Modify → Parameters

Main Parameters

• t = 3 mm → material thickness (MDF)
• w = 10 mm → slot width
• h = 20 mm → slot depth
• L = 40 mm → central body length
• W = 40 mm → central body width
• e = 20 mm → side extension length
• n = 1 → slot per side
• kerf = 0.15 mm → laser kerf compensation

PARAMETRIC RELATIONSHIPS

Overall Dimensions

• Total Width = W + (2 × e)
• Total Height = L + (2 × e)

Substituting the values:

• Total Width = 40 + (2 × 20) = 80 mm
• Total Height = 40 + (2 × 20) = 80 mm

Slot Dimensions

Each slot:

• Width = w = 10 mm
• Depth = h = 20 mm

Slot Position:

• Centered on each side
• Distance from centerline = 0 mm
• Slot center aligned with horizontal and vertical axes

Laser Fit Compensation

For a press-fit assembly:

• Material thickness = t = 3 mm
• Kerf = 0.15 mm

Actual slot:

• slot = t − kerf
• slot = 3 − 0.15
• slot = 2.85 mm

This adjustment provides a tighter fit after laser cutting.

HOW TO FIX IT IN FUSION

1. Go to Modify → Parameters
2. Create:
   • t = 3 mm
   • w = 10 mm
   • h = 20 mm
   • L = 40 mm
   • W = 40 mm
   • e = 20 mm
   • kerf = 0.15 mm
3. Edit the sketch:
   • Replace each 10 mm slot width with w
   • Replace each 20 mm slot depth with h
   • Replace each 40 mm center section with L and W
   • Replace each 20 mm side extension with e
4. Use:
   • Symmetry
   • Rectangular Pattern
   • Constraints

The model was developed using parametric design, defining key variables such as tooth width (w), socket depth (h), material thickness (t) and drilling diameter (d). These variables allow the geometry of the part to be modified automatically, adapting to different configurations and materials. Repetition through patterns and symmetry was used to ensure uniformity in the laces.

3. Kerf Consideration

The kerf of the laser cutter (material removed during cutting) was considered as a key factor in the design.

Based on the tests carried out in the group activity, the dimensions of the grooves were adjusted to compensate for the loss of material, achieving an adequate fit.

Assembly tests were performed to validate the fit:

• Firm Fit
• Stable parts
• No need for glue

4. Laser cutter manufacturing

The design was exported in vector format (. DXF) and processed in the laser cutter software.

Prior to cutting, the correct configuration of the file was verified, ensuring that the lines were defined as vectors and ready for cutting.

It was used as a 3mm MDF material, suitable for press-fit assembly testing.

Parameters used:

• Material: MDF 3 mm
• Power: 30%
• Speed: 70mm/s

During the process, a stable cutting behavior was observed, obtaining continuous lines without interruptions. The result was to obtain parts with defined edges and precise dimensions.

The parts were then removed and evaluated for fit, confirming that the design is suitable for assembly without the need for adhesives.

5. Construction Kit

The construction kit developed is based on a parametric modular part designed to generate multiple three-dimensional configurations through repetition and assembly.

The system uses press-fit joints, where the parts are pressed together without the need for adhesives. To achieve a proper fit, the thickness of the material (t = 3 mm) and the manufacturing tolerance (kerf) were considered, incorporating a compensation of 0.2 mm, which allowed defining functional grooves with a firm fit.

The design was developed under a parametric approach, using variables such as:

• t (material thickness)
• C (Tolerance/Kerf)
• W, H (Dimensions)
• d (diameter of perforations)
• n (geometric repetitions)

These variables allow the design to be modified in a controlled manner, adapting it to different materials and scales.

The geometry of the part allows it to be assembled in multiple directions, generating different configurations through the repetition of the module. As a result, stable structures are obtained, which do not fall apart when manipulated, evidencing the correct application of modular design and digital manufacturing principles.

Vinyl Cutting Machine

Graphic precision applied to institutional identity

The vinyl cutting process was developed using the Roland CAMM-1 Servo GX-24, a high-precision machine widely recognized in digital manufacturing environments for its reliability and accuracy in tracing.

The work was carried out with the Roland CutStudio software, a tool that allows you to convert digital designs into vector paths ready for cutting, optimizing lines, curves and typographic details.

From the moment the machine is turned on and displays its active control panel, the machine is ready to transform a design into a tangible physical application. The clear and functional interface allows you to configure the material, adjust parameters and verify the correct alignment before starting the process.

https://www.rolanddga.com/es-la/productos/software/roland-cutstudio-software

Design Preparation in CutStudio

We open the study cut program,

The workflow started with the import of the graphic file:

5. Archive
6. Import
7. Selecting the design in JPG format

Once the image was uploaded, the vectorization process was performed, extracting the contour lines to convert the raster image into cutting paths.

In this case, the program was worked on directly:

• The size and proportions were adjusted.
• The preview of the material was checked before cutting.

The correct prior configuration allows to guarantee that the stroke is clean and continuous, avoiding incomplete or excessive cuts.

Only the cut contour remains

Cutting Process

With the material correctly placed on the Roland CAMM-1 GX-24, the cutting option was selected, which displayed the final configuration window.

The team executed the layout with precision, faithfully following the lines generated in the software. The combination of mechanical calibration and digital tracing made it possible to obtain defined cuts, without damaging the base support of the vinyl.

Application in the Institutional Environment

As part of the practical process, the designs were applied in the Academic Secretariat of the institution, strengthening the visual identity of the space.

Once the design was already cut in vinyl, the rest of the material that is not part of the design was peeled off and pasted on the Fab Lab Huando blackboard

In addition, the institutional name and the digital manufacturing logo were placed on one of the furniture in the area, showing how cutting technology can be integrated into real projects to improve the educational environment.

This experience not only allowed us to understand the technical operation of the machine, but also to demonstrate its potential to transform spaces through applied graphic design.

Some more designs that were cut in vinyl

Post-Process (Weeding and Transfer)

Once the cut is finished:

• The lines were carefully checked to ensure that the cut was complete.
• The excess material was removed manually (a process known as weeding).
• Even discarded parts that could be reused in future projects were preserved.
• The figure was transferred to the destination, carefully applied to avoid bubbles or misalignments.

Finally, evidence of the work concluded was left on the Roland machine itself where it was produced, closing the complete cycle: design → cutting → application.

During this week I understood that computer-controlled cutting does not depend only on sending a file to a machine, but on understanding how each parameter directly influences the final result. I learned that factors such as kerf, power, speed, and material type determine cutting accuracy and assembly quality.

The development of the parametric kit allowed me to understand the importance of adaptive design and actual manufacturing tolerances. Through fit and calibration tests, I found that a small error in the measurements can completely affect the operation of the press-fit system.

I also understood that digital manufacturing requires a constant validation process: design, test, correct, and remanufacture. This was evident in both laser cutting and vinyl cutting, where each adjustment improved accuracy and the final finish.

In addition, working with the Roland GX-24 allowed me to see how graphic design can be integrated into real applications within the institutional environment, transforming digital files into functional and visually professional physical elements.

Finally, this week reinforced my understanding of the relationship between digital design and physical manufacturing, demonstrating that accuracy, planning, and testing are critical to obtaining functional and quality results in digital manufacturing processes.