3. Computer Controlled Cutting

G. Group Assignment

A. Group Assignment 1 Characterise Laser Cutter

Characterize your lasercutter's focus, power, speed, rate, kerf, joint clearance and types. I had done this with my team mate in 2022 at Singapore Polytechnic. Here is the link to the site.

Characteristic Description
Focus The focal point of the laser beam determines the precise area where the laser's energy is concentrated for cutting or engraving. Focus is adjusted using the laser cutter's focus control mechanism. For Epiloog Mini 24, I will be using its Autofocus function.
Power The strength of the laser beam, measured in watts (W), determines the cutting and engraving capabilities of the laser cutter. Higher powered lasers can cut through thicker materials and engrave with greater depth.
Speed The rate at which the laser cutter moves along the cutting path, measured in millimeters per second (mm/s) or inches per minute (IPM). Speed affects the cutting time and quality of the cut edges.
Rate The frequency at which the laser cutter pulses on and off during cutting or engraving, measured in hertz (Hz). The pulse rate affects the thermal characteristics of the cut and engraved surfaces.
Kerf The width of the cut produced by the laser beam, which varies depending on the material and settings used. Kerf width is typically small but can impact the fit of interlocking parts.
Joint Clearance The space required between mating parts to ensure a proper fit when assembled, taking into account the width of the laser cut. Joint clearance is critical for achieving precise assembly without interference.
Types The different types of joints or connections that can be created using the laser cutter, such as butt joints, finger joints, or dovetail joints. Joint type selection depends on the design requirements and material properties.

I. Individual Assignment

I1. Individual Assignment- Parametric Design Kit Design on Onshape

Vector Tools
Steps Description
0. Measure Thickness of Material to Cut and Laser Kerf Laser Cutting Steps Use Vernier Calipliers or Digital Calipers to measure the thickness of the material required for press fit
1. Creating Sketch of Rectangle, Slots, Construction lines and Constraints
Laser Cutting Steps		 Begin by launching Onshape and creating a new document. Use the sketch tools to outline the shape of the parametric design kit. Incorporate rectangles for the main components, slots for interlocking connections, and construction lines for alignment. Apply geometric constraints to ensure that the sketch remains fully defined and adjustable as you refine the design.
2. Using Dimension Tool And Variables to Constraint
Laser Cutting Steps		 Next, utilize the dimension tool to add precise measurements to your sketch. Assign variables to parameterize key dimensions, such as the length, width, and thickness of components. This allows for easy adjustments later on by simply modifying the variable values. Apply geometric constraints to link dimensions and maintain the desired proportions of the parametric design kit. Ensure that the design remains adaptable to accommodate variations in material thickness or specific project requirements.
3. Export Face to DXF
Laser Cutting Steps		 Export the finalized sketch face to a DXF file format. This file format is commonly used for exporting 2D vector graphics and is compatible with many laser cutting machines. Make sure to specify the desired units and scale during export to ensure accurate dimensions when cutting the design on a laser cutter.
Digital Files Created Onshape File
Stl File

I2. Parametric Design Kit Design on CorelDRAW

CorelDRAW Steps
Steps Description
1. Import DXF Launch CorelDRAW and import the DXF file containing the finalized sketch of the parametric design kit. Use the import options to adjust settings such as units, scale, and layers as needed. Ensure that the imported sketch appears accurately in CorelDRAW's workspace.
2. Select Engraving and Laser Cutting Identify the parts of the design that require engraving and laser cutting. Use CorelDRAW's drawing and editing tools to separate the design elements into distinct layers or groups based on their intended treatment. Assign appropriate colors or line styles to indicate engraving areas versus cutting paths.
3. Set Engraving Parameters Define the engraving parameters for the identified areas, such as laser power, speed, and resolution. Adjust these settings based on the material being used and the desired engraving depth or quality. Preview the engraving to ensure it meets your expectations before proceeding to the cutting stage.
4. Set Cutting Parameters Specify the cutting parameters for the laser cutter, including power, speed, and frequency. Take into account the material thickness and properties to determine the optimal cutting settings. Use CorelDRAW's tools to generate cutting paths or adjust existing paths as needed for accurate and efficient cutting.
5. Arrange for Efficiency Organize the design elements on the CorelDRAW workspace to minimize material waste and optimize cutting efficiency. Arrange components closely together while maintaining sufficient spacing to prevent interference during cutting. Consider the order of operations and nesting techniques to maximize the utilization of the material.
6. Export to Laser Cutter Prepare the design for export to the laser cutter's software. Verify that all engraving and cutting settings are correctly configured and that the design is correctly positioned within the cutting area. Export the design in a compatible file format, such as AI or DXF, for seamless integration with the laser cutter's software.
Digital Files Created DXF File

I3. Parametric Design Kit Design on Laser Cutting

Laser Cutting Steps
Steps Description
1. Safety Checks
Laser Cutting Steps		 Prior to operating the laser cutter, conduct thorough safety checks to ensure the machine and work environment are safe. Verify that all safety features are functioning correctly, such as emergency stop buttons, interlocks, and exhaust systems. Wear appropriate personal protective equipment (PPE) as required by organisation.
2. Using Epilog Mini 24 Steps
Laser Cutting Steps		 If using the Epilog Mini 24 laser cutter, follow these steps:
  1. Power on the laser cutter, filter and air assist pump and ensure laser cutter is properly calibrated and aligned.
  2. Load the material onto the cutting bed, ensuring it is securely positioned and flat.
  3. Open the design file in the laser cutter's software and verify the settings, including power, speed, and frequency.
  4. Run a test cut or engraving on a scrap piece of material to verify the settings and alignment.
  5. Once satisfied with the test, initiate the cutting or engraving process on the actual workpiece.
  6. Monitor the operation closely and be prepared to pause or stop the laser cutter if any issues arise.
  7. After the cutting or engraving is complete, remove the finished pieces from the cutting bed and inspect them for quality.
  8. Power off the laser cutter and properly clean and maintain the machine for future use.
3. Post-Processing
Laser Cutting Steps		 After completing the laser cutting process, perform any necessary post-processing steps, such as removing any protective masking from engraved surfaces, sanding edges for smoothness, or assembling components as required by the design. Ensure that the finished pieces meet the desired specifications and quality standards.

I4. Vinyl Cutting on Cricut Maker 3

Laser Cutting Steps
Step Description
1. Safety Checks
  • Prior to operating the vinyl cutter, conduct thorough safety checks to ensure the machine and work environment are safe. Verify that all safety features are functioning correctly, such as emergency stop buttons, blade guards, and ventilation systems. Wear appropriate personal protective equipment (PPE), including safety glasses and gloves.
2. Designing At Software
Laser Cutting Steps
  • Insert Designed Text and Logo. Use Size tool and dimension to scale the log. Use Boolean Operations when required.
2. Material Setup
Laser Cutting Steps
  • Load the smart vinyl material onto the cutting mat and ensure it is securely positioned and aligned.
3. Setting Adjustments
Laser Cutting Steps
  • Set the appropriate cut settings in the Silhouette software, including blade depth, speed, and pressure, based on the type and thickness of the vinyl material. As I am using smart vinyl, I did not have to reference the settings.
4. Cutting Process
Laser Cutting Steps
  • Send the design to the vinyl cutter from the Silhouette software and initiate the cutting process.
  • Monitor the cutting process closely and be prepared to intervene if any issues arise, such as material misalignment or blade skipping.
5. Post-Cutting Process
Laser Cutting Steps
  • Once the cutting is complete, carefully remove the cut vinyl from the cutting mat and weed out any excess material.
  • Finish the vinyl cutting process by transferring the cut design onto the desired surface using transfer tape or adhesive.

R. References

R1. References A. Coreldraw

Reference Description Link
CorelDRAW Official Tutorials Official tutorials provided by Corel for new users to learn the basics of CorelDRAW. Visit Tutorials
CorelDRAW User Guide A comprehensive guide covering all aspects of CorelDRAW, perfect for deep dives into specific features. Download User Guide
CorelDRAW Community Forums A place for users to share t , ask questions, and discuss all things related to CorelDRAW. Join the Discussion
CorelDRAW Discovery Center Resource for inspirational content, tutorials, and t to enhance creativity and productivity. Explore Discovery Center

R2. References B.Epilog Mini 24

Reference Description Link
Mini/Helix Laser Manual A manual providing step-by-step instructions for the Mini and Helix laser systems, detailing how to use your laser system. Mini/Helix Manual
Epilog Knowledge Base The support center for all Epilog laser machines, offering a vast knowledge base for troubleshooting, maintenance, and operational guidance. Knowledge Base