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16. Wildcard Week

Assignment

  • Design and produce something with a digital process (incorporating computer-aided design and manufacturing) not covered in another assignment, documenting the requirements that your assignment meets, and including everything necessary to reproduce it. Possibilities include (but are not limited to):

For Wildcard week I decided to learn Zund g3 cutting machineand make a miniature cardboard prototype of my final project.

Zünd Overview

  • Company: Zünd Systemtechnik AG
  • Specialty: High-precision digital cutting systems
  • Features:
    • Modular design for tailored configurations
    • Advanced drive system for optimal performance
    • Precision cutting blade for clean, accurate cuts
  • Applications: Versatile across industries, including textiles, graphics, packaging, composites, and leather

  • Benefits:

    • Exceptional flexibility to meet specific production requirements
    • High efficiency and productivity with consistent, high-quality results
    • Adaptable to various materials, enhancing workflow versatility

  • Website: zund.com

  • The G3 Cutter is a precision machine, meticulously engineered with perfectly coordinated components from the innovative drive system to the cutting blade. Zünd’s modular design concept allows you to create a customizable cutting solution tailored to your specific production needs. This flexibility ensures that the G3 Cutter can adapt to various applications, providing unparalleled efficiency and precision in every cut. Whether you’re working with textiles, graphics, packaging, or other materials, the G3 Cutter delivers consistent, high-quality results that enhance your production capabilities.

  • I first scale down my Nap-Pod design and export all the required files in dxf format.

  • Then I power up the Zund machine.

  • I start the zund.

  • Hit F1 to begin initializing the machine. (the operating screen will tell you that you can start with F1). DO NOT touch anything while the machine initializes itself. The modules will come towards the PC and operating screen once initialization is done.

  • Initializing the tools: There are three modules in the ZUND. On startup, we have to initialize all the modules.

  • Universal Module Tool ZS (Zünd Scoring) • ZS = “Scoring” or “Oscillating” Module • Typically holds an Electric Oscillating Tool (EOT) or Universal Cutting Tool (UCT) • Ideal for cutting or scoring soft to medium-density materials like:
  • Foam, Corrugated cardboard, Textiles, Rubber

  • Uses a reciprocating (up-and-down) motion for cleaner cuts

  • Universal Module Tool ZP (Zünd Pressure/Perforating) • ZP = “Pressure” Module, typically used for:

  • Creasing wheels, Scoring tools, Perforating tools • Great for packaging applications, especially when working with:

  • Corrugated board, Folding carton • Applies constant pressure rather than oscillation

  • Router Module (RM) • A high-speed rotary tool for cutting rigid and hard materials • Suitable for:

  • Acrylic, PVC, Wood, Aluminum, Foamcore • Comes with:
  • Dust extraction system
  • Often has cooling options

Each module slot accepts different types of processing modules.

The operating screen will begin with module 1. Auto initialize all the module as show below in the series of screenshot.

  • Here is the list software available to work with Zund.

  • Cut Server • This connects the PC and the machine to the same server. • You don’t need to make any changes here.

  • Cut Editor • This is where you edit your design. • You also choose the material and assign processes here.

  • Cut Manager • This stores all hardware, tools, and material settings. • You don’t need to change anything unless you want to add a new material.

  • Cut Queue • This is where all your jobs are listed. • New and old jobs appear here after you finish in Cut Editor.

  • Cut Center (not shown) • This is the final step. • Here, you assign [text incomplete in original]

  • Then I opened Cut Editor and define the size of the cardboard.

  • And then import my dxf files and I arranged my files properly. I specify the cut method as through cut. Also I added register method to set the coordinate of the cardboard put on the zund.

There are many processing methods. Each method is different depending on the material. I used only two method. Register method to set the coordinates of the cardboard(job piece) using camera inbuilt in the zund and cut method to cut my design. In general, there are three methods: i. Cutting method ii. Creasing method iii. Register method

For register method, I choose border front right.

To assign a method: - Select a line or multiple lines in your design. - Right-click on the selected lines. - Then click Change Method and choose New Method.

  • We can also assign the methods in order like in first register > crease> thrucut in a sensible sequence so that zund with make the right sequence of method.

  • After setting up the design in the cut editor, send it to cut queue by clicking on the top left the send to server icon which looks like a letter doc with an arrow.

  • Your job will be saved and sent to cut queue.

  • Next hit online on the machine to connect it to PC.

  • Double click the job and it will be opened in cut center as shown below.click the Start Job button at the bottom right. If everything is set up correctly, the button will have a green border around it. If there is a problem, the button will show an orange border instead. The machine will then display a message to tell you what the issue is, so you can fix it before starting.

We can also edit the cut depth and check whether the tool setting are done correctly of not.

once you hit the start job, register process will begin. Utilize the pc’s arrow keys to align the camera with the right border first and hit Enter. Then align it with the bottom border and hit enter. This will Register the borders after which your Job will begin.

Once your work is done, shutdown the machine by pressing together the two keys together as shown below.

  • Put off the main power as well.

  • Here is a video of Zund in operation.

  • Here is me assembling my mini Nap-pod prototype.

  • Final Result

Design files

i. Scaled Down NapPod Design Fusion360 file. ii. DXF files used in Zund Cutting.