Wildcard Week

Design and produce something using a digital process (incorporating computer-aided design and manufacturing) that is not covered in another assignment, documenting the requirements your task meets and including everything necessary to reproduce it. Some possibilities include, but are not limited to,Examples of the wildcardweek .

Exploration of Hybrid Digital Manufacturing Processes

Cover Image

General Description

In this activity, different products were developed using hybrid digital fabrication processes not fully addressed in previous Fab Academy tasks.

The work integrated various digital design and manufacturing technologies, including:

• Computer-aided design (CAD)
• Digitally controlled laser cutting
• Thermal sublimation
• 3D printing
• Application of adhesive vinyl using a cutting plotter

The main objective was to experiment with different digital manufacturing flows applied to materials such as MDF, ceramic, PLA and adhesive vinyl, allowing the transformation of digital designs into personalized and reproducible physical products.

This activity also allowed for an understanding of the integration between digital design, machine configuration, and manufacturing processes applied to different types of materials and surfaces.

Why does this project belong to Wildcard Week and how does it differ from other assignments?

This project corresponds to Wildcard Week because it integrates multiple hybrid digital fabrication processes within the same workflow, combining technologies that were not developed together in previous weeks of Fab Academy.

Unlike other assignments, where each process was worked on individually, this activity integrated various digital technologies, including:

• Computer-aided design (CAD)
• Digitally controlled laser cutting
• thermal sublimation
• 3D printing
• Cutting adhesive vinyl using a plotter
• Customization using UV DTF technology

In addition, graphic transfer and personalization processes were applied to different surfaces and materials such as MDF, ceramics and PLA, allowing the development of functional, personalized and reproducible physical products.

The activity also allowed for experiencing complete integration between:

• digital design
• file preparation
• machine parameter configuration
• digital manufacturing
• Finishes and final customization

The combined use of additive manufacturing, computerized cutting, sublimation, and personalization technologies made it possible to obtain results with more complex visual and functional finishes than those developed in other tasks of the program.

Project 2 — Mug Sublimation

Project 3 — 3D Printing and Customization with Vinyl and UV DTF

My process:

Project 1 — Sublimated Puzzle on MDF

1. Vector Design of the Puzzle
   • Vector Design of the Puzzle
   • The puzzle design was developed in Corel Draw using vector design tools to prepare for both the laser cutting and sublimation process.
   • During this stage, the following activities were carried out:
   • Definition of the overall dimensions of the board
   • Design and division of the puzzle pieces
   • Vector line configuration for laser cutting
   • Organization of the fitting areas
   • Preparing the image for the sublimation process
   • Design adjustment to ensure correct alignment between printing and cutting
   • The digital file was prepared considering the precision of the cut and the correct distribution of the pieces to guarantee a functional assembly of the puzzle.

Preparation for Laser Cutting

Once the vector design was completed, the file was exported and configured for shipment to the laser cutter.

During this stage, the following were verified:

• design dimensions
• vector cutting lines
• position of material
• workspace configuration
• correct laser focus

The sublimable MDF was carefully placed on the workbed to ensure stability and precision during the cutting process.

Laser Cutting of MDF

The cutting process was performed using computerized control with the vector lines previously designed in Corel Draw.

The laser cutter automatically followed the digital paths set in the file, allowing for precise, uniform, and correctly sized pieces to be obtained for assembling the puzzle.

In addition, the quality of the cut was continuously checked to ensure a clean finish and a correct fit between the pieces.

Cut Result

After the laser cutting process was completed, all the puzzle pieces were obtained with precise dimensions and defined edges.

The pieces were carefully separated from the MDF to verify:

• quality of cut
• precision of the fittings
• uniformity of forms
• cleaning the edges

The result yielded a set of functional parts ready for the sublimation process and final assembly.

Puzzle Sublimation

After the laser cutting process, the thermal transfer of the image was performed on the surface of the sublimable MDF.

To do this, the design, previously printed on sublimable paper, was carefully placed on the puzzle and secured to prevent movement during the application of heat.

Subsequently, the material was introduced into the heat press to perform the ink transfer using controlled temperature and pressure.

Parameters Used

• Temperature: 200°C
• Time: 60–120 seconds
• Pressure: Uniform adjustment on the surface

During the process, it was verified that the temperature and time were adequate to achieve a homogeneous transfer and correct image definition on the MDF.

Final Puzzle Result

The final result was a custom puzzle made of sublimable MDF, combining laser cutting and thermal transfer in the same digital manufacturing flow.

The final product presented:

• functional and correctly assembled parts
• uniform printing
• good image definition
• correct alignment of the sublimated design
• clean and personalized finish

The integration of vector design, computerized cutting, and sublimation made it possible to transform a digital file into a reproducible and visually appealing physical product.

Project 2 — Mug Sublimation

General Description

In this activity I developed a custom graphic design to sublimate onto a mug using vector design tools and a thermal transfer process.

The goal was to integrate:

• 2D digital design
• Preparing a file for printing
• Sublimation parameter settings
• Controlled heat transfer process

This activity combines computer-aided design with digital manufacturing applied to customized products.

1. Digital Design in Corel Draw

The design was created in Corel Draw, where the logos for the following were created:

• IES HUANDO

Document settings

A base rectangle was created with:

21 cm x 9 cm

This size corresponds to the usable print area for an 11-ounce mug.

Design Process

• The Spline tool was used to vectorize and adjust curves.
• Color was applied using the CMYK palette.
• The design was mirrored horizontally, as sublimation requires printing in mirror mode.
• The design was replicated on an A4 sheet to make the most of the material and produce three cups.
• The file was exported in the following format: .JPG – CMYK color mode

2. Sublimation Printing

The following was used:

• Printer: Epson L1250
• Special ink for sublimation
• Special paper for sublimation

The paper is similar to bond paper, but contains a specific coating for thermal transfer.

3. Preparation for Sublimation

The paper was placed around the cup and secured with thermal tape to prevent movement.

1. Sublimator Configuration

Equipment used:

Subliflex – Mug Sublimation Machine

Configured parameters:

• Temperature: 200°C
• Time: 2 minutes
• Pressure: Manually adjusted with lever

The cup was placed in the center of the equipment to ensure even transfer.

1. Final Result

At the end of the time:

• The cup was removed using thermal gloves.
• It was left to cool for 10 minutes
• The paper was carefully removed

The result was a personalized mug with uniform color transfer and high definition.

Digital Workflow

2. Vector design in Corel Draw
3. Size adjustment 21x9 cm
4. Horizontal reflection
5. Export JPG
6. Printing on sublimable paper
7. Thermal preparation
8. Controlled heat transfer
9. Finished product

Technical Considerations

• Insert the cup only when the equipment reaches 200°C.
• Always remove using thermal gloves.
• Check for correct pressure to avoid discolored areas.
• The design should be printed on the white part of the sublimation paper.

Project 3 — 3D Printing and Customization with Vinyl and UV DTF

3D File Preparation

For this project, the digital preparation of an experimental anatomical model of an artificial rabbit vagina was carried out for the 3D printing process.

The design was worked on and edited in Tinkercad software, where adjustments were made to shape and dimensions to obtain a printable model.

Subsequently, the file was exported in STL format and prepared in Cura software, where the necessary parameters were configured to ensure a stable and accurate print.

During this stage, the following were configured:

• model orientation
• layer height
• printing speed
• extruder temperature
• base adhesion
• print support
• estimated manufacturing time

Finally, the file was converted into print paths (G-code) to be sent to the 3D printer.

3D Printing

The experimental anatomical model was manufactured using 3D printing with PLA filament and the layer-by-layer additive manufacturing process.

Once the G-code file was prepared in the slicer software, it was sent to the 3D printer to begin the physical manufacturing of the part.

Printing Process

During the process, the printing parameters were constantly monitored to ensure stability and quality in the final result.

It was monitored:

• correct adhesion of the part to the print bed
• stability of material flow
• extruder temperature
• uniformity of the printed layers
• dimensional accuracy of the model
• continuity of the printing process

The printing was done progressively by controlled deposition of molten thermoplastic material, forming the complete geometry of the 3D model.

Cutting and Application of Vinyl and UV DTF

Subsequently, the 3D printed piece was customized using adhesive vinyl and UV DTF technology with the institutional logo of IES Huando.

The CutStudio software was used for the adhesive vinyl cutting process, where the dimensions, paths and parameters necessary for the digital cutting of the institutional logo were configured.

The file was sent to the cutting plotter to accurately produce the design on the adhesive material.

Likewise, for the UV DTF customization process, the graphic design was prepared in Corel Draw, where the following adjustments were made:

• logo dimensions
• graphic composition
• design distribution
• visual print quality

Subsequently, the UV DTF design was applied to the surface of the 3D printed part to obtain a more detailed and durable visual finish.

During this stage, the following was verified:

• correct configuration of the designs
• material alignment
• vinyl cutting accuracy
• adhesion of the adhesive material
• correct UV DTF transfer
• cleaning the application surface

The integration of adhesive vinyl and UV DTF technology significantly improved the customization and visual finish of the 3D printed part.

Application of Vinyl and UV DTF

After the cutting and preparation process, the adhesive vinyl and UV DTF design were carefully applied onto the 3D printed piece.

During this stage, the following was verified:

• alignment of the institutional logo
• correct adhesion of the material
• surface cleaning
• absence of bubbles or deformations
• accuracy in the placement of the design

The application allowed the piece to be customized using digital finishing and graphic transfer techniques.

DTF UV Printing Process

In addition to adhesive vinyl, UV DTF (Ultra Violet Direct Transfer Film) technology was used to customize and improve the visual finish of the 3D printed piece, allowing the incorporation of graphics with greater quality, resistance and surface detail.

The objective of this stage was to integrate graphic elements directly onto the surface of the final product, achieving a more professional and aesthetic appearance.

Graphic design preparation

The design was developed and edited in Corel Draw software, where different parameters were configured to ensure correct printing and transfer of the graphic.

During this stage, work was carried out on:

• Adjusting design dimensions according to the size of the part
• Print quality settings for the Epson L805 printer
• Organization and graphic distribution of visual elements
• Image resolution and definition settings
• Preparing lines and edges to improve transfer
• Color and contrast verification
• Optimizing the file for UV printing

Subsequently, the final design was exported and sent to the UV DTF printer to begin the printing process on the special transfer film.

DTF UV film printing

During the printing process, the machine deposited the UV ink directly onto the transparent film using instant ultraviolet curing.

This procedure allowed us to obtain:

• Intense and defined colors
• High design adhesion
• Greater surface resistance
• Glossy, professional finish
• Good definition in small details

UV DTF technology offers significant advantages over conventional vinyl, as it allows the transfer of complex designs without the need for individual cutting of each graphic element.

Protective laminate

Once the UV printing was completed, a clear protective laminate was applied over the design.

This laminate serves several functions:

• Protect UV ink
• Facilitate the transfer
• Improve the durability of the chart
• Prevent landslides
• Increase resistance to abrasion and moisture

The lamination process was carried out carefully to avoid:

• Air bubbles
• Misalignments
• Wrinkles on the film

Transfer onto the printed piece in 3D

After lamination, the base film was removed and the manual transfer was performed on the surface of the 3D printed part.

During this stage, the following was considered:

• Correct design alignment
• Uniform pressure on the surface
• Pre-cleaning of the piece
• Waste or dust disposal

The graphic was carefully adhered onto the printed structure, achieving a clean and uniform visual integration.

Finally, the top film was slowly removed, leaving the design completely adhered to the piece.

Final Result

The final result was a piece manufactured using 3D printing in PLA and customized using adhesive vinyl and UV DTF technology.

The integration of additive manufacturing, digital cutting, and graphic transfer made it possible to develop a functional, personalized, and visually appealing product through various digital manufacturing processes.

Problems Encountered and Solutions

Problem 1 — Burnt edges on MDF

Solution

The laser power was reduced and the speed was adjusted.

Problem 2 — Uneven Transfer in Sublimation

Solution

The thermal pressure and transfer time were readjusted.

Problem 3 — Poor vinyl adhesion

Solution

The surface was cleaned before applying the adhesive material.

Problem 4 — Partial detachment of UV DTF

Solution

Uniform pressure was applied and the surface cleanliness was checked before the transfer.

Learning achieved

During Wildcard Week I learned to explore new tools, processes and complementary technologies within the digital manufacturing flow, integrating creativity, experimentation and personalization in the development of the final project.

This week allowed me to understand that digital manufacturing is not limited solely to electronics or programming, but also includes finishing processes, visual identity, customization, and aesthetic improvement of the product.

I learned:

• To use new digital personalization technologies such as UV DTF.
• Prepare graphic designs for digital manufacturing.
• To integrate visual design with 3D printed parts.
• To combine software and hardware tools within the same workflow.
• To improve the appearance and final presentation of a product.
• Experimenting with materials, finishes, and transfer processes.
• To optimize printing parameters and graphic quality.
• To apply lamination and transfer processes on physical surfaces.

Furthermore, I understood the importance of:

• The visual presentation of the final product.
• The integration between graphic design and digital manufacturing.
• Experimentation as part of learning.
• Detailed documentation of tests and results.
• Creativity applied to technological projects.

This experience strengthened my multidisciplinary skills, allowing me to integrate electronics, design, manufacturing, and customization within a single functional and user-oriented project.

📋 Check-off List

1. Did you document the workflow(s) and process(es) used?

Yes. The processes of CAD design, laser cutting, sublimation, 3D printing, vinyl cutting, and UV DTF customization were documented.

2. Did you explain how your process is not covered in other tasks?

Yes. This week it integrated hybrid processes of digital manufacturing and personalization that were not jointly developed in previous weeks.

3. Did you describe the problems you encountered and how you solved them?

Yes. Problems such as burnt edges, poor vinyl adhesion, and sublimation errors were documented, along with their technical solutions.

4. Are the original design files and source code included?

Yes. Original files from CorelDRAW, Tinkercad, Cura, and configurations used for digital fabrication were included.

5. Was a "master shot" of the result included?

Yes. Final images of the manufactured products were included: sublimated puzzle, personalized mug, and 3D printed piece with vinyl and UV DTF.

❓ Frequently Asked Questions

1. Can I do the homework by hand?

Answer:
Yes, but in this project the main workflow was digital. The following processes were used:

• CAD design in CorelDRAW and Tinkercad
• Computer-controlled laser cutting
• 3D Printing
• Cutting plotter
• Thermal sublimation
• UV DTF Customization

Although there were manual steps such as:

• Apply thermal tape,
• assemble parts,
• apply vinyl,
• Remove supports,

The design, configuration, and manufacturing relied on reproducible digital files and digitally controlled processes, meeting the Wildcard Week requirement.

2. Do I have to do the group assignment if I choose to do composites?

Answer:
Yeah.

During Wildcard Week, it is necessary to document tests or experimentation of the process used.

In this case, although traditional composites were not used, the following were performed:

• laser cutting tests,
• sublimation tests,
• 3D printing tests,
• vinyl adhesion tests and UV DTF,
• Digital parameter configuration.

These tests serve the function of experimental validation of the hybrid digital manufacturing process.

3. Do I need to manufacture something tangible?

Answer:
Yes, although the most important thing is the reproducible digital flow.

In this project, functional and personalized physical objects were indeed manufactured:

• Sublimated puzzle on MDF
• Sublimated mugs
• Custom 3D printed parts with vinyl and UV DTF

Each product was generated from:

digital file → machine setup → digital manufacturing → final finishing.

Therefore, the project fully meets the criterion of transferring digital files to reproducible physical objects.

4. Can I perform 3-axis machining for my Wildcard task?

Answer:
Yes, as long as it is not exactly the same process carried out in previous weeks.

This project did not use 3-axis CNC machining, but rather a hybrid integration of:

• laser cutting,
• 3D printing,
• sublimation,
• vinyl,
• UV DTF.

The main difference compared to other weeks is that here:

• Multiple digital technologies were combined into a single workflow
• Different materials and surfaces were used
• Personalization processes and digital finishes were added
• Additive manufacturing, computerized cutting, and graphic transfer were integrated.