3. Computer-Controlled Cutting¶
Hero Shots¶
This week, we are delving into the intricacies of the cutting process, focusing on the operation of vinyl and laser cutter machines. We are gaining proficiency in the use of a vinyl cutter, as well as learning how to maintain and operate laser cutters. To assess the equipment and successfully complete the task, we have been cutting out various components.
Laser cutter¶
Group assignment¶
You can read more about our group assignment here.
Our instructor introduced us to safety techniques and how to take care of the machine. During the group task, we discussed how a laser machine can ignite and how to react in this case.
For Example
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Periodically clean the lenses and mirrors reflecting the laser beam.
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When igniting the material, do not blow on the fire.
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Do not extinguish the flame with water.
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Use a fire extinguisher.
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Monitor the temperature of the water cooling liquid.
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Avoid excessive contamination of the air filter.
After that, we changed the filters.
And cleaned the lenses.
Next, we started experimenting to understand the thickness of the slice, the strength and speed of the laser, as well as the depth of the engraving.
After that, we created a test file to determine the optimal settings in terms of speed and power. We measured the internal and external dimensions of the cut, we realized that the kerf is 0.15 mm.
Individual assignment¶
For this week’s assignment, I wanted to try a flexible joint and started drawing it in SolidWorks.
Using parametric modeling, I can dynamically adjust the thickness of the material and the size of the joint.
Here’s how I did it.
On the Tools tab, I selected Equations. In the window that opened, we can see Global Variables, where I added the thickness of the material. In the Equations, I selected the sketch fragments and the size was related to the thickness of the material. You can also add a formula to automatically shift the kerf.
After that, I can easily set up joins by changing the variable in Global Variables.
I created a sketch on which I drew the basis for the flexible part of my design.
After that, I created a pattern based on it, and then fillet off all the necessary corners and used a Circular Sketch Pattern to repeat it on the remaining two parts.
Due to unforeseen circumstances, I was unable to attend the laboratory for several days. As a result, I decided to use a laser cutting machine at my workplace to complete my project.
To do this, I first conducted a test to determine the ideal joint size and at the same time checked how this machine performs engraving at different speeds and at different powered levels.
I created a simple template with a measurement for joints ranging from 3 mm to 3.30 mm in an intermediate step of 0.05 mm.
I checked the engraving at three speeds 200, 250 and 300 with a force of 16 to 28 increasing by 2, and for cutting 3 mm plywood, I set the speed to 30 and the force to 60. After I set all the parameters in the program, I uploaded the file to the machine and started the cutting process.
These are the samples I have received.
I have a kerf of 0.12 mm, and since the thickness of the plywood varies between 3.8 mm and 3.13 mm, I left the connection size at 3 mm, taking into account the kerf size.
I adjusted the thickness in SolidWorks, then exported the drawing to a laser cutting program and set the aforementioned cutting settings. And that’s what I got.
The cut parts fit together perfectly, leaving no gaps and holding very well.
Vinyl cutter¶
This is my first time working with a vinyl cutting machine. First, I studied the instructions for operating it.
In our laboratory, we use a Roland GX24 vinyl cutter.
Group assignment¶
Here you can observe the components that make up the vinyl cutter.
The device has a user-friendly interface with buttons for easy operation.
After turning on the machine, we need to specify which type of material we will use, piece, edge or roll. Before starting work, it is important to adjust the position of the wheel for fixing the material so that it matches the size of the material, and make sure that the paper is smooth and there are no wrinkles on it. This will prevent the paper from tearing while the machine is running. It is also important to position the material so that it covers the optical sensor. The machine bypasses the entire surface of the material and automatically makes measurements of the working plane. Before starting the process of cutting out the protective sign for the laser cutter, I conducted preliminary testing to determine the pressure exerted by the knife during operation.
The test included a gradual increase in pressure from 30gf to 180gf in 30gf-fold increments.
I open the pre-prepared file in Inkscape and go to the “File” menu in the top panel. Then, I press the “Print” button or use the Ctrl + P key combination. After that, I select the printer from the list, go to the “Preferences” menu, click “Get from Machine”,then click “OK” and “Print”. click “OK”, and the file is printed.
Since my sticker has a variety of colors, I had to cut out each color individually from the vinyl and arrange them in one place for later application to the surface.
I used paper duct tape to secure each piece in place, wiped the area where I would stick it with alcohol, and then attached the sticker to the machine. Subsequently, I smoothed the tape with a card to ensure a smooth and even attachment.
Individual assignment¶
I had an idea to create something interesting using a vinyl cutter, and I decided to bring it to life by trying to create origami using a cutter. First, I tried to create a more complex form. I went to the Origami Simulator website and read about what the file should be for proper stimulation. In the drawing, it was necessary to add certain colors or lines.
- Boundary edges and any internal hole have black stroke - rgb(0, 0, 0), hex #000000
- Mountain folds have red stroke - rgb(255, 0, 0), hex #ff0000
- Valley folds have blue stroke - rgb(0, 0, 255), hex #0000ff
- To control the triangulation, draw the lines in yellow - rgb(255, 255, 0), hexadecimal #ffff00
- To create slots in the form of a green line - rgb(0, 255, 0), hexadecimal #00ff00
- Undefined folds that bend at a specific angle have a magenta outline - rgb(255, 0, 255), hexadecimal #ff00ff
With this information, I began to draw my own pattern.
This is exactly the process I followed to upload an SVG image to the simulator.
To adjust the degree of paper bending, simply move the slider.
However, due to the excessive pressure exerted on the paper, which prevents it from taking the desired shape, I decided to change the drawing to a simpler version.
Opening the drawing in the simulator again, I was satisfied with the result and decided to create this particular model.
Using a vinyl cutter, I scratched the lines I needed on paper, removed the yellow lines for simulation, and loaded the drawing into the vinyl cutter and started the process. I started slowly bending the paper in the right places and got this shape. And then I fixed the necessary edges with tape.
Conclusion¶
TThis week has been really exciting for me and full of new knowledge and experience. I especially enjoyed working with a vinyl cutter — it’s a fairly easy-to-learn tool, but the cutting process itself turned out to be incredibly interesting. I realized how important it is to properly prepare files, take into account the material characteristics and select the optimal cutting parameters in order to get a neat and high-quality result. Now I’m confident that I’ll be able to apply this skill in future projects, whether it’s creating stickers, stencils, or decorative elements.
In addition, I realized how much the laser cutter expands the possibilities of production. It can be used to implement a variety of ideas, from detailed layouts to functional products. This tool allows you to work with a wide range of materials, and the precision and cutting speed make it indispensable for a variety of tasks. Now I am even more inspired to create unique projects using it.
I also had to study parametric functions in SolidWorks, which turned out to be extremely useful. This approach automates the design process and significantly reduces work time. Instead of manually rebuilding the model when changing parameters, you can now set relationships and dependencies, so that the entire structure automatically adjusts to the new values. This not only saves time, but also helps to avoid mistakes that could occur with manual adjustments. Mastering parametric modeling has opened up new perspectives for me, and I’m looking forward to putting this knowledge into practice.
Overall, this week has been a great experience for me, helping me deepen my understanding of digital production and inspiring me to experiment further. I am glad that I can develop my skills in such an interesting and creative field!