Parametrics Design for lasercutting
This week, I designed a parametric lamp for the laser cutting process. I used Fusion 360 because it offers great options for parametric design and allows objects to be saved perfectly as vector graphics (DXF).
Additionally, it enables the creation of 3D models, providing a preview of how the final design will look.
The best part of this project is its flexibility—it can be created in multiple ways, such as starting with a small lamp and expanding it into a larger version through modular extensions.
And the ende you can find a the project files. But first of all lets start what i did:
1. Project Setup
Open Fusion 360 and open a save your project before you start (e.g., “3. assignment_parametric_Lamp.f3d”). Create a Component to keep your design organized and make assembly easier.
1.1 Creating the Support Ring (First Component)
Start a Sketch & Define Parameters: At first i create a new sketch on the XY plane. Draw a circle (⭘) and set its diameter as a parameter (e.g., lamellaholder). Copy this circle and offset it by a specific distance (Distance_Rings parameter) so that both rings scale together when the parameter is modified.
This is a button for offset.
Also a option is to define the second ring with click on the first ring and it will be a code(e.g.d4) and make a invoice (e.g. *4).
1.2 Using Parameters for Dependencies
Go to Modify > Change Parameters and create the following parameters: Wood (material thickness (e.g., 3 mm) Cutout_Slates plug (Wood +Kerf) Kerf Kerf/2 Use variables within your sketch, e.g.,plug=wood(material tickness - kerf -0,28mm).
1.3 Creating plug for the Lamellae and some circle cutouts for a better fit.
Create a rectangular plug in the sketch that can be repeated in a circular pattern. Set constraints so that all plugs are dependent on the first copy.
1.4 Creating the Lamp Lamellae (Second Component)
Create a new component for the lamellae. Open a new sketch and reference the previously defined parameters (Material_Thickness,plug, Cutout_Slates). Draw the lamella shape, ensuring that it fits into the cutouts.
1.5 Adding a Second Ring (Third Component)
Create another component for the lower ring. Use a parametric sketch again to ensure that this ring automatically adjusts when parameters change. Use the height for an other parameter( this is not a perfect parameter because i used spinelines for the lamella and you can´t change the value at any height).Only from 50mm to 150 mm it works good. Next to this the form of the spinelines change to some different forms.
Here you can see a 150mm long lamella lamp only with changing one parameter
Here you can see a 70mm short lamella lamp
1.6 Assembling & Arranging the Lamellae
Assemble the components and position them correctly. Use the circular pattern function (Modify > Pattern > Circular Pattern) to distribute the lamellae evenly around the ring. Now, any changes to the parameters will automatically adjust the entire design.
2. Laser Cutting Process
2.1. Save the Project as a DXF File
In Fusion 360, save your project as a DXF file (there is a plug-in for Fusion 360) -> click here for the dxf plug-in.
Right-click on your component, select the DXF option, and click on the object face you need for the cut.
This will generate a DXF file.
For every body, I create a separate file to keep things organized.
The file name should include the parameter values so you can easily differentiate between them, e.g.,
lamellaholder1_3.5mm_3.7cutout.dxf
2.2. Laser Cutter & Software
I work with a GS System laser cutter (150W).
The software I use to modify the laser cutting settings is RDWorks, which is the proprietary software provided by the laser cutter manufacturer (not open-source).
2.3. Importing & Preparing the Files in RDWorks
Open RDWorks and import the DXF files.
Change the color to the cutting color (in RDWorks, this is usually Red).
Adjust the cutting settings based on the material and laser power.
2.4. Testing & Adjustments
First, I cut two lamella holders and one lamella as a test.
Initially, the pieces did not fit well.
I adjusted the tolerance of the plug connection, and on the second cutting attempt, it worked perfectly.
The issue was that I didn’t initially account for the kerf (the width of material removed by the laser). The laser cuts along the center of the line, affecting the final fit.
Also, in the DXF plugin, there is a standard kerf, and I didn’t change it initially. So my kerf appeared on the parameter list, and I changed the DXF plugin to 0 mm kerf.
If you use the plugin, you can also change the kerf there if you want. But for my parametric design, I want the kerf to be in the parameter list.
You can find more details about this in my group assignment.
2.5. Assembly & Modular Expansion
Once everything fits well, no glue or screws are needed—the lamellae simply click into the rings.
I created two different heights to demonstrate how the parameters affect the design.
Additionally, I added a third ring (lamellaholder2) to extend the lamp vertically.
This makes the design infinitely expandable, following a modular system.
## Here are my files for lasercutting:
dxf lamellaholder1 dxf lamellaholder2 dxf lamella
And here is the Step file for construction: