Documentation

Week 1: Principles and Practices

In the first week, we talked about the course structure and the basics of Git and Git CI. We also developed and deployed the first basic version of a website that will document our progress throughout the course.

I wanted to make my website look more presentable with Hugo static site generator. I haven’t worked with Hugo before, so it was an interesting experience. It was nice to choose from variety of themes, the only thing I struggled with were the default icons. The second thing was the Final Project idea, which I haven’t thought much yet. Thinking of making a “smarter” furniture perhaps.

Week 2: Computer-Aided Design

This week we started to look at 2D and 3D modelling. The aim was to try different modelling tools such as Fusion360 or FreeCAD.

It was interesting to hear that we should try to have the sketches fully constrained at the end of sketching/modelling. I was aware of the parametrisation feature in Fusion and used it a lot, but never noticed the degrees of freedom.

OpenSCAD

When I first heard about this software, I was intrigued because you use programming to model something in 3D. There is no need to have sketches since you can directly model the 3D object.

Week 3: Computer-Controlled Cutting

Group Assignment

The page describing the group assignment for this week (kerf measuring, and testing different speed and power) can be found here.

Laser Cutting

This week we started to learn about laser cutting. We were introduced to the laser cutter in the lab, and our task was to try to play with the settings and cut something as a project.

Preparations:

Getting the laser cutter ready

Safety first - ventilation must be on (maxed), and we need to make sure that the fire blanket and fire extinguisher are present. We need to watch the laser cutter at all times that it is on (there is also a small device that will ask you once in a while whether you are still present).

Figure 1: Device that beeps to check if you are present
Place the material in the laser cutter. The laser cutter can cut different materials -> we did the test cuts with cardboard as it is the cheapest one, then we tried the wood of different thickness
It is important to calibrate the distance between the laser cutter and the material so that we get the best focal point. There is a metal thing attached to the laser with a magnet that can be freed, and it should be just touching the material below, so there is a bit of friction. If there’s not, we should adjust the laser cutter setting to either lift or push it down. NOTE: some laser cutters can do this automatically (even the one we have in lab, it was just broken for a bit) - when you are importing the material settings, there is an “Auto Focus” option there, which is “Off” by default, but we can set it to “Plunger”

Getting the design ready

Prepare the design we want to “print” -> this should be a 2D design that will be cut out. Note that the product will be 3D, but the third dimension is just the thickness of the material we are cutting. The design should be in an appropriate (vector) format such as .dxf, .svg, .eps or .pdf.
Open your design in Adobe Illustrator. Make sure all the lines you want to cut are 0.01mm thick.
After we are satisfied with the design, we can try to “print” it (control P), which will open the print dialogue. There is a special add-on for the laser cutter, as seen on image bellow. Change the “Media Size” to Custom.

Figure 2: Adobe Ilustrator print
After selecting print, you should see the live image of what’s happening inside the laser cutter in a new program (at this point all the steps of “Getting the laser cutter ready” should be completed, and the laser cutter turned on) -> as seen on image bellow. If the camera doesn’t work, restart the laser cutter.

Figure 3: Laser cutter program
Place the piece where you want it on the image. Make sure it’s not too close to other edges (it can ruin the cut).
Make sure that there is a vector and the engraving for the correct things.

Figure 4: Vector and Engraving
Select the right settings for the material you are using (there are pre-defined settings for different materials), adjust them if needed.

Figure 5: Different setting
You can select “Start cutting” on the computer. Then select the correct file name on the laser cutter display, and press play. The cutting should start now.

Figure 6: Press Play

Practical tips:

The laser cutter is connected to a computer next to it. It is nice to have the design prepared on a USB drive. The other option is to log in using the Aalto account, but that might take a bit of time
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Week 4: Electronic Production

This week, we learned how to do the PSB milling. We started by generating a toolpaths, then preparing the Roland SRM-20, and after the milling was done, soldering the finished board. This was the first week when I had multiple things go wrong (at least 3 unsuccessfully milled board), but I also learned a lot, and now I make PCBs quite often.

Group Assignment

The page describing the group assignment for this week (characterize the design rules for your in-house PCB production process) can be found here.

Week 5: 3D Scanning and Printing

This week we worked with 3D printers. We focus on learning what a 3D printer can do and its limitations. On this page I will summarize what I know and my discoveries.

Group Assignment

The page describing the group assignment for this week (test the design rules for your 3D printer) can be found here.

Backgroung

I was first introduced to 3D printing (and to a concept of a rep rap printers) in 2020, with an old Prusa printer.

Week 6: Embedded Programming

This week we worked on embedded programming. We were given a Seeed XIAO RP2040 board from Seeed studios. Overview: https://wiki.seeedstudio.com/XIAO-RP2040/

Group Assignment

The page describing the group assignment for this week (demonstrate and compare the toolchains and development workflows or alternative embedded architectures) can be found here.

Soldering

The useful tutorial to soldering headers here.

I did solder some stuff before, but I am still need more practising. Should’ve watched more tutorials. I like that there are quite a few tools in the lab (such as flux pen and desoldering braid), was happy to get to try all of them.

Week 7: Computer-Controlled Machining

Group Assignment

The page describing the group assignment for this week (runout, alignment, fixturing, speeds, feeds, materials, and toolpaths for our machine) can be found here.

Introduction

This week we are working with the CNC (computer numerical control) milling machine to make a bigger piece (such a table or shelf). I haven’t worked with the CNC milling machine before, so this was the most challenging week so far. We have two such machines in lab - big and small one. I will be talking only about the big one, the Recontech 1312 milling machine.

Week 8: Electronic Design

This week we were working on Electronic design - PCB design. PCB stands for Printed Circuit Board, and it is a board that connects electronic components and provides a pathway for electrical signals to travel between them. It can be very useful to make a custom PCB for a specific project, as this can save space and there won’t be that many cables.

Group assignment

The page describing the group assignment for this week (using the test equipment to observe the operation of a microcontroller circuit board) can be found here.

Week 9: Output devices

Week 10: Machine Building

We decided to build a machine that has an ultrasonic welder attached, so it can melt plastics together - to simplify the making of inflatables.


Figure 1: The final machine		Figure 2: Inflatable we made

The two pictures above were not taken by me, and are from our group assignment page.

The whole process is documented on our group assignment page, which can be found here.