Lei Feng Fab Academy 2025

Appearance

Week 03: Computer-Controlled Cutting ​

Overview ​

As the third week of Fab Academy 2025, Professor Neil led us to explore computer-controlled cutting technologies in depth. This week's course focused on two main tools: Vinyl Cutter and Laser Cutter. These tools provide essential capabilities for digital fabrication, enabling us to precisely transform digital designs into physical objects. The course emphasized safe tool usage, understanding material properties, and the importance of parametric design in practical applications.

Key Course Points ​

  1. Cutting Tools Overview

    • Vinyl Cutting: From basic signage to complex flexible circuits
    • Laser Cutting: Precise 2D cutting and engraving, and creating 3D assembly structures
    • Other Cutting Techniques: Plasma cutting, waterjet cutting, hot wire cutting, etc.

  2. Vinyl Cutting Technology

    • Applications: Signage, heat transfer, pop-up cards, origami/kirigami, screen printing, circuit making
    • Material Selection: Vinyl, copper foil, epoxy film, masking tape
    • Process Parameters: Cutting force, speed, depth, temperature and humidity effects
    • Key Techniques: Material feeding control, weeding techniques (adhesion, lifting vs cutting)

  3. Laser Cutting Technology

    • Basic Principles: Stimulated emission, beam characteristics, focusing principles
    • Cutting Mechanisms: Burning, melting, vaporization, ablation
    • Process Flow: Air assist, exhaust system, optical path maintenance
    • Safety Management: Ventilation requirements, fire prevention, operating procedures

  4. Materials and Applications

    • Cardboard: Edge crush strength, directional considerations
    • Acrylic: Cutting, bonding, bending techniques
    • Wood: Custom material requirements
    • Fabric: Cutting parameter optimization
    • Special Materials: Safety and compatibility considerations

  5. Parametric Design Practice

    • Press-Fit Structure Design: Clearance control, stress concentration, parameter testing
    • Living Hinges: Flexible mechanisms, mechanical devices
    • Kerf Compensation: Handling laser beam width effects
    • Assembly Systems: Diverse connection methods

Core Tools ​

  • Cutting Equipment: Cricut/Cameo (vinyl), Epilog/Universal/Trotec (laser)
  • Design Software: FreeCAD (parametric design), Inkscape (vector editing)
  • Process Control: Dedicated drivers, cutting path optimization tools

Assignment Requirements ​

This week's tasks include:

  1. Group Assignment:

    • Complete lab safety training
    • Characterize laser cutter parameters: focus, power, speed, frequency
    • Test kerf width, joint clearance and types

  2. Individual Assignment:

    • Complete a project using vinyl cutter
    • Design and laser cut a parametric construction kit:
      • Consider laser cutter kerf compensation
      • Implement multiple assembly methods
      • Bonus: Include non-planar elements

Safety and Precautions ​

  1. Laser Cutting Safety

    • Always supervise the cutting process near the machine
    • Ensure ventilation system is functioning properly
    • Understand fire prevention and handling procedures
    • Regularly clean optical components

  2. Material Safety

    • Avoid cutting materials from unknown sources
    • Prohibit cutting harmful materials like PVC
    • Ensure materials are suitable for the equipment

Learning Resources ​