4. Computer controlled cutting¶

This week’s assignment was to utilize the vinyl cutter for cutting, design a laser-cut item, and document a parametric construction kit. This kit should consider the laser cutter kerf and be designed to be assembled in various configurations.

Vinyl cutter¶

A vinyl cutter is a versatile tool that is used to create a wide range of products from custom gifts to signs and banners. It is a computer-controlled cutting machine that uses a small blade to precisely cut vinyl material into various shapes and designs.

ADVANTAGES OF USING¶

A vinyl cutter is a must-have tool for anyone looking to create custom products with precision and ease. One of the key advantages of using a vinyl cutter is the level of precision and detail that it provides. The small blade size allows us to follow intricate patterns and designs, making it the perfect tool for creating intricate stickers, decals, and wall art. This precision also means that we can create clean, accurate cuts every time, ensuring that our final product is exactly what we envisioned. Another advantage of using a vinyl cutter is its cost-effectiveness. You won’t have to spend a lot of money on expensive equipment or materials, and the vinyl material itself is relatively inexpensive.

What we can make with vinyl cutter¶

Stickers and decals: Vinyl cutters are perfect for creating custom stickers and decals.
T-shirt designs: A vinyl cutter is a great tool for creating custom t-shirt designs.
Wall art: Vinyl cutters can be used to create beautiful wall art that is both functional and stylish. From simple quotes and sayings to intricate patterns and designs, a vinyl cutter is a perfect tool for creating wall art that is sure to impress.
Signs and banners: A vinyl cutter is an ideal tool for creating signs and banners. Whether you need a sign for your business or you want to create a custom banner for a special event, a vinyl cutter is a perfect solution.

Tips¶

Choose the right vinyl material: Some types of vinyl are more durable than others, so it’s important to select the right type for project. Consider the intended use of product and choose a vinyl that is appropriate for it needs.
Use a cutting mat: A cutting mat is an essential accessory for any vinyl cutter. It helps to protect workspace and provides a stable surface for cutting, which can result in more precise cuts.
Transfer tape: Transfer tape is a clear plastic material that is used to transfer cut vinyl designs to a surface. This makes it easier to position the design precisely, and it also protects the design during the transfer process.
Practice and experimentation: Like any new skill, it takes time and practice to master using a vinyl cutter. Experiment with different vinyl materials, blade sizes, and cutting techniques to see what works best for our projects
Store vinyl rolls properly: Vinyl material can be sensitive to heat , light, and moisture, so it’s important to store it properly.

To ensure correct and safe usage with a full understanding of this product’s performance, is important to read manual. Improper handling or operation of this machine may result in injury or damage to property. As previously emphasized, understanding the instructions is crucial. To provide a clearer explanation, I’ve opted to share images from the instruction manual alongside photos I captured during hands-on sessions at the FabLab Academy Dilijan.

Part Names and Functions¶

Cutting carriage - the part where we install blade holder.It moves to the left and right and cut the materials. knife guide - this part help cut off te material without first removing the material from the machine. pinch roller- this part clamps the material when the loading level is raised.

Display Test key pressing and holding tis key for a second or longer cuts a pre-registered test patterns. Origin key pressing and holding tis key for a second or longer sets the origin point at the present location of the blade. Cursor keys We use this keys to perform such operations like moving the cuting carriage or material and selecting and setting various menu items. Pen force slider with this slider we can fine-tune the blade force, even we can change it while cutting is in progress.

Practicing Cutting¶

Here are sequential steps for vinyl cutting. 1. Loading the material. 2. Pull out the material until its leading edge is positioned over the guide lines. 3. Align the material. 3. move the pinch rollers so that they are positioned at the edges of the material and inside the areas of the pinch-roller position verification marks. 4. switch on the power to the machine and make it ready to receive data from the computer.

Material such as the test-use material that is pre-cut to a certain length is called “flat material.” When you’re using ordinary flat material, choosing [PIECE] displays the width and length. However, if the length exceeds 1.6 meters, the length is not displayed when [PIECE] is chosen. If you’re using flat material whose length is more than 1.6 meters, choose [ROLL], then make sure the material does not come loose.

To obtain high-quality cutting results, before I performed the actual cutting, I carried out a cutting test to check the cutting quality for the material.

After loading the materials and doing the test, the next step involves deciding on the design for vinyl cutting.

There were two options: safety rule stickers for the 3D printer or stickers for my computer.

I decided to try both. Here is the sequence of steps to cut the sticker designed using the Inkscape program.

At the outset, I chose the hairline measurement unit (representing the very faintest surface scratches) for the stroke and removed any fill.

After that, using the Ctrl+P shortcut, I opened the print window and selected the Roland GX-24 device.

Then, I accessed the Preferences menu for the cutting area, where I chose the “Get from machine” option to retrieve the width and length calculated by the device.

Of course, after encountering several failures and gaining a better understanding of what was achievable, I attempted to produce a relatively satisfactory version. The initial error stemmed from applying either too much or too little force. Eventually, I found that the optimal force setting was 150 gf.

First Failure

Second try and failure

The last failure

Better versions

After cutting, here are the steps to remove the material. Press Menu button to display UNSETUP option and press Enter after that the cutting carriage returns to the standby position. Lower the loading lever we can remove the material.Holding down the power button for one second for switch off power.

Laser cutting¶

Group assignment page ¶

It’s important to follow safety rules during laser cutting to avoid serious consequences. Here are some of them. 1. Personal Protective Equipment (PPE): Always wear appropriate PPE, including safety glasses with side shields to protect your eyes from laser radiation, as well as gloves to shield your hands from potential burns. Note: that not all types of lasers require the use of gloves and glasses, when it have lid it isn’t necessary. 2. Ventilation: Ensure proper ventilation in the laser cutting area to prevent the buildup of fumes and smoke produced during cutting. Use exhaust systems or ventilation fans to remove airborne contaminants. 3. Material Compatibility: Use only materials approved for laser cutting and engraving. Some materials, such as PVC or vinyl, can emit toxic gases when cut with a laser, posing health hazards. 4. Fire Safety: Keep the laser cutting area clear of flammable materials, and have fire extinguishing equipment readily available. Regularly inspect and maintain the laser cutter to prevent overheating and potential fire hazards. 5. Operator Training: Ensure that operators receive proper training on the safe operation of the laser cutter, including how to load materials, set parameters, and handle emergencies. 6. Restricted Access: Limit access to the laser cutting area to authorized personnel only. Post warning signs and labels to indicate the potential hazards and safety precautions. 7. Emergency Procedures: Establish emergency procedures for accidents, injuries, or equipment malfunctions. Know how to shut down the laser cutter and evacuate the area safely in case of an emergency. 8. Regular Maintenance: Schedule regular maintenance and inspections of the laser cutter to ensure it operates safely and efficiently. Replace worn parts, clean optics, and perform calibration as needed.

Safety rules are displayed on the laser machine at the Dilijan FabLab to ensure a safe working environment.

Once familiar with the safety features, it’s crucial to comprehend its components and maintenance requirements to ensure its long-term, smooth operation.

Here are parts

Laser Tube: The laser tube is the heart of the CO2 laser system, where the laser beam is generated. It contains a mixture of gases, typically carbon dioxide, nitrogen, and helium, which are excited by electrical discharge to emit laser light.

Power Supply: The power supply provides the electrical energy needed to excite the gases in the laser tube and generate the laser beam.

Mirror System: The mirror system consists of mirrors that reflect and direct the laser beam along the desired path, typically towards the workpiece. This system helps control the beam’s trajectory and focus.

Lens: The lens focuses the laser beam to a small point on the surface of the workpiece, increasing the intensity and precision of the cutting or engraving process.

Control Panel: The control panel is the interface used to operate the CO2 laser system. It allows users to input settings such as laser power, cutting speed, and other parameters.

Cooling System: The cooling system is responsible for maintaining the optimal operating temperature of the laser tube. It typically consists of a water chiller or circulation system to dissipate excess heat generated during laser operation.

Exhaust System: The exhaust system removes fumes, smoke, and debris generated during laser cutting or engraving to maintain a clean and safe working environment.

Safety Interlocks: Safety interlocks are mechanisms that ensure the CO2 laser system operates safely. They may include emergency stop buttons, door sensors, and other safety features to prevent accidents and injuries.

Cleaning the laser cutter lens is an essential maintenance task to ensure optimal performance and quality of cuts or engravings. Here are steps.

Power Off: Before cleaning the lens, ensure the laser cutter is powered off and unplugged to prevent any accidental activation of the laser beam.
Access the Lens: Depending on the design of your laser cutter, you may need to remove a protective cover or access panel to reach the lens. Follow the manufacturer’s instructions for accessing the lens safely.
Remove Debris: Gently blow away any loose debris or dust from the lens surface using a can of compressed air or a clean, dry brush. Avoid using your breath to blow away debris, as moisture can accumulate on the lens.
Apply Lens Cleaner: Apply a small amount of lens cleaner specifically designed for optical lenses to a clean, lint-free microfiber cloth. Do not apply cleaner directly to the lens to avoid drips or excess liquid.
Clean the Lens: Gently wipe the lens surface in a circular motion, starting from the center and working outward. Be careful not to apply too much pressure or scrub vigorously, as this can scratch the lens.
Inspect for Residue: After cleaning, inspect the lens surface for any remaining residue or streaks. If necessary, repeat the cleaning process using a fresh microfiber cloth and lens cleaner.
Reinstall the Lens: Carefully reassemble any protective covers or access panels and reinstall the lens in the laser cutter according to the manufacturer’s instructions.
Test the Cutter: Power on the laser cutter and perform a test cut or engraving to ensure the lens is clean and the machine is operating correctly.

Here are the supplies we have for cleaning the lens.

The laser cutter’s focus, power, speed, and rate are key parameters that determine the quality and efficiency of the cutting process. Here are the closest parameters

Here are steps to focus C02 laser cutter.

Prepare Material: Place the material you want to cut or engrave onto the bed of the laser cutter and secure it in place. Adjust Bed Height: Use the manual controls or software interface to adjust the height of the bed so that the material is at the correct focal distance from the laser. Focus Tool: To find the right focal distance, utilize a focusing tool like a focusing gauge or lens. This distance varies based on the material and the lens in your laser cutter. Ensure the visible laser dot aligns vertically with the laser end during this process. Adjust Lens: If necessary, adjust the position of the lens in the laser cutter to achieve the correct focal distance. Some laser cutters have manual focusing mechanisms, while others may have automatic focusing features. Final Check: Once the focus is set, double-check the focal distance and ensure that the material is securely positioned before starting the cutting or engraving process.

Wrong focus

Right focus

After focusing the laser, it’s important to measure the kerf. Kerf is the width of material that is removed by a cutting process. Here’s how we did it:

Prepared Test Material: We took a small piece of the cutting material.
Made Test Cut։ We designed two squares, one inside the other.
Measured Cut Width: Use a caliper and to measure the width of the cut lines. Measure multiple points along each cut to get an average width.
Calculated Average Kerf: After measurements from multiple cuts, we calculated the average width of the cuts. This gave us the kerf width for our laser settings and material. Here is the photo of calculating kerf .

Kerf=10-9.75=0.25

Adjust Settings: Depending on the desired precision of your cuts or engravings, we may need to adjust our laser cutter settings to compensate for the kerf width. This could involve adjusting the design files or the laser cutter parameters.

Designing and cutting a parametric construction kit¶

I did my parametric design with FreeCad. Here are steps. At first I designed the the primary sketch․

After that I chose Spreadsheet workbench and selected create spreadsheet option.

I renamed the spreadsheet to “Params” and listed the names of the parameters that I wished to be changeable and add display units and alias(In FreeCAD’s parametric design, an alias refers to an alternative name given to a parameter or variable).

After that, I added dimensions to my primary sketch, and all dimensions were taken from the parametric spreadsheet and sketch became fully defined.

After that, I changed the parameters for segment numbers and the top angle to construct the other parts of the kit. Then I saved it as a DXF file and imported it into RDWorks software to prepare for cutting with the laser cutter machine. On the right side of the screen, you can see the speed and power settings that I configured for the cutting process.

Here is my final construction kit

Conclusion¶

I had never used a vinyl cutter before, so it was interesting for me, especially since I can make both stickers and PCBs with it.

I had used a different type of laser cutter before, so I already had known how laser cutting works. This helped me understand the laser cutter we used in the FabLab Academy better.

I also learned about parametric design in FreeCAD, which was a new for me. It was a bit challenging at first because I need decide what part of design need be parameters.It makes really easy make the similar design and have different sizes. Overall, my experience with the vinyl cutter, laser cutter, and parametric design in FreeCAD was really interesting. I learned a lot and had fun exploring new ways to create things.