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3. Computer-Controlled Cutting

Summary

This time, we explored the appropriate parameters for the laser cutter in a group work setting. After that, each of us came up with our own designs, cut them out from cutting boards using the laser cutter, and assembled them.

Today’s Local Session Page

https://fabacademy.org/2025/labs/kannai/instruction/week03/

0. My Preparations

0-1. Personal Efforts - Review from Project Members

Starting this week, I introduced a new initiative. That is to have this page reviewed by other project members I am working with.

There are three reasons for this.

The first reason is that since I am creating documentation, I wanted to present myself with more diverse and practical benefits, not just for my own learning. If I can anticipate the readers, the explanatory text and content will be refined, and it will also motivate me to create this document. Above all, one of my beliefs is that “documents that are not used will rot.”

The second reason is that I have the motivation to improve my abilities by accepting a wider variety of questions. Many predecessors have said that teaching something ultimately leads to one’s own learning. From the perspective of David Kolb’s “Experiential Learning Model,” reconstructing one’s understanding and conveying it to others promotes deep reflection and conceptualization, and from the perspective of Bloom’s taxonomy, it is believed to activate “analysis,” “evaluation,” and “creation,” thereby promoting deep understanding and retention of knowledge for learners. (In Japan, the well-known learning pyramid has a certain number of critical reviews regarding its effectiveness and basis, so I intentionally did not list it as a basis for my claims.) In any case, I believe that the act of conveying something to others, receiving questions, interpreting the meaning of those questions, and providing appropriate responses enhances my own abilities.

The third reason is that I have come to believe that this act clearly contributes to the progress of actual projects. I am currently planning products for two new projects. In each project, I am the only one who understands product development the best. This means that I cannot discuss product aspects to some extent when considering functional additions, requirement organization, or service design. Discussions can only take place among those who share a common knowledge base. Therefore, by sharing the information I have input, I believe I can increase opportunities for others to empathize with the knowledge background of the concerns and assumptions I have.

In any case, this document is becoming more visible to a larger number of people, which can be said to enhance the value of the document itself. Yay!

0-2. Let’s Deepen Our Understanding of the Laser Cutter!

Before attending the actual local session on Saturday, I needed to deepen my understanding of the laser cutter.

To be honest, the reason is that I do not currently feel attracted to the laser cutter.

I think one reason for this is that it feels distant from my motivation to create three-dimensional objects. The second reason is that I believe I do not know much about laser cutters.

Therefore, I decided to conduct a comprehensive investigation.

Research Method

  1. Create prompts using GPTo3 mini high

    • Prompt

      If I want to comprehensively research laser cutters using LLM, what kind of prompts would be effective? Please create 5 prompts for researching different content.

    • LLM Response

      Here are five prompt examples to delve into various aspects of laser cutters.
1. **Basic Principles and Comparison of Types**  
　"Please explain the basic principles of laser cutters in detail. In particular, comprehensively compare the operating principles, characteristics, advantages, and disadvantages of various types such as CO₂ lasers, fiber lasers, and YAG lasers."

2. **Applications and Industrial Use Cases**  
　"Please explain the main applications and use cases of laser cutters, including specific examples. Also, describe the utilization methods and success stories in various fields such as manufacturing, healthcare, design, and crafts, as well as the effects of implementation."

3. **Safety Measures and Work Environment Precautions**  
　"Please detail the safety measures and precautions in the work environment when using laser cutters, including risk management, appropriate protective measures, and points for environmental management during work. In particular, please address measures for potential troubles and guidelines based on regulations."

4. **Maintenance and Troubleshooting**  
　"Please explain the regular maintenance methods for laser cutters and common failure cases, along with troubleshooting procedures, in a way that is easy for beginners to understand, including practical advice on parts replacement timing and cleaning points."

5. **Latest Technologies and Market Trends**  
　"Please provide a comprehensive analysis of the latest laser cutter technologies and future market trends, including the current state of technological innovation, comparisons with competing products, and future predictions based on examples of collaboration with smart factories and IoT."
By using these prompts, you can comprehensively research and deepen your understanding of laser cutters from basic knowledge to the latest trends.

  2. Research will be conducted by genspark deep research based on specific prompts created by GPTo3 mini high.

    1. Diverse Applications of Laser Cutters and Their Effects
    2. Comprehensive Analysis of Latest Laser Cutter Technologies and Market Trends
    3. Laser Cutter Maintenance and Troubleshooting Guide
    4. Complete Guide to Laser Cutter Safety Measures: Standards, Measures, and Emergency Response

    If you have not used Genspark deep Research, please allow me to recommend it: Genspark deep Research researches and aggregates a great deal of information.Of course , it is not a good idea to take the report at face value. but there is no substiute for the experience of asking Genspark deep Research for a few quick ideas or questions before going to bed and gaving a research report the next morning.

  3. Collect sites where patterns for laser cutters can be downloaded using felo ai

    • Brief explanation about felo ai
      • Japanese search LLM
      • Can search not only web but also specific genres like papers
      • I think the following features are very useful.
      • It creates mind maps
      • Allows you to choose between markdown and regular copy when copying
      • You can share this page itself
      • Has a transfer function to Notion
      • Has a presentation function
  4. I recorded the behavior of felo ai, so I will share it.

Changes in Perception of Laser Cutters Based on Research

  • Laser cutters can handle a variety of materials such as glass, wood, metal, paper, and plastic. This is a strength that 3D printers do not have, and I felt it is a very important perspective from the viewpoint of food safety.
  • The mechanism of material processing using laser light involves heating the material, causing it to melt or evaporate. The basic processing style is to cut or evaporate using heat. This poses a risk of fire.
  • The advantage of laser cutters is that they allow for non-contact processing, meaning they can process materials without direct contact. This eliminates the need for material wear and tool replacement, reducing maintenance effort. I think this is a very good advantage because it also reduces the effort of polishing the material itself.
  • Examples of laser cutter applications in manufacturing include the production of complex parts in the automotive industry and the manufacturing of lightweight and strong parts in the aerospace industry. This contributes to the efficiency of the manufacturing process. In electronics manufacturing, they are used for cutting and drilling circuit boards, enabling fine processing. Precise board processing that was not possible in traditional factories can now be done easily. This is revolutionary. Speaking of which, I remember local instructor Tamiya saying something like that.
  • Additionally, they are used in the production of design lighting and furniture using wood and acrylic, making it possible to realize unique designs at low cost. They are also suitable for producing complex designs and small lot production in stage art, allowing for efficient production. Indeed, stage art requires a variety of props for the story (and they often break…). If materials can be easily processed into parts, not only can desired items be easily made from raw materials, but maintenance and repairs will also become easier.
    • Upon further thought, most of Japan’s traditional crafts involve the time and effort of intricate designs through fine carving and processing. Nowadays, both can be processed computably.

  • The aspect of being used in medicine was a blind spot. Indeed, YAG lasers are used in beauty hair removal. If the output is changed, it may also be possible to perform surgery with lasers instead of a surgeon’s scalpel. Minimizing cuts can significantly reduce damage to cells, which is very attractive.

    Websites to Download Laser Cutter Patterns for Free

  • Laser Cut Patterns (981) Files Free Download - 3axis.co

  • Laser Cut Files, Download Templates, Designs & Patterns For Free
  • Free Laser Cutting SVG Files & Templates | Instant Download
  • Laser Cut Pattern Vector Art, Icons, and Graphics for Free Download
  • 1000+ Free Laser Cutting Files for Any Decoration - DesignFind
  • Free Vectors, Templates, 2D CAD Drawings and Laser Cut Projects
  • Website to Purchase Laser Processing Data “Etsy” | Laser Processing Dojo | Comnet

Cutting Material

  • Be careful with cardboard, as the cross-section varies depending on the orientation.
  • Adjust the focal length of the laser cutter.
  • Try changing the power and speed.

1. Laser Cutter Setting Parameters

  • PPI (Pulses Per Inch)
  • Speed
  • Power (Output)

Variables to Consider

  • Kerf
    • The area of material lost when cutting.
    • This is very important, so it’s good to set it as a parameter when doing parametric design in Fusion 360 or similar software.
  • Joint Clearance
    • The fit is also important.

Kerf Bending

  • If processed with a laser cut, materials like wood can also be bent.

    • Individual Assignment * Design, laser cut, and document a parametric construction kit, * accounting for the laser cutter kerf, * which can be assembled in multiple ways, * and for extra credit include elements that aren’t flat.
    • Individual Assignment * Cut something on the vinyl cutter.

2. Individual Assignment

Assignment Content: Design a Parametric Construction Kit, Laser Cut, and Document It

Additional Notes

  • Consider the cut of the laser cutter,
  • It should be able to be assembled in multiple ways,
  • For extra credit, include elements that aren’t flat.

Step 01: First, Check What Predecessors Have Done

I wasn’t sure where to start, so I looked at what some people did on the 2024 site page.

Step 02: Generate Ideas

  • Consider designs that take time constraints into account.
  • It would be good to have something usable during the lecture.
  • How about a charging stand that considers the charging port?
  • I feel like I’m starting to see some ideas.

step03: Consider requirements and specifications from ideas

  • Requirements
    • Must be able to charge
    • Smartphone screen should be easy to see
    • Must also be able to charge earphones
    • Minimalistic
  • Specifications
    • Charging cable
      • Consider the tip of the charging cable
      • Ensure the charging cable is easy to reuse for both smartphone and earphones
    • Smartphone
      • It is acceptable for the bottom 1cm of the screen to be hidden
      • It would be nice if the angle could be adjusted
        • Adjust the angle with an additional insert
    • Earphones
      • Place in front of the smartphone
      • A shape that makes it easy to take out the earphones is preferable
    • Paper jacket
      • It would be nice if it could be propped up

step04: Try visualizing

Write down ideas as they come to mind

Problem: I don’t know how to break down and draw the parts

I decided to ask Hayashi-san , who I am learning with in Kannai, to teach me how to write design drawings. What I need is a friend.

Upon investigation, I learned that drawings in the field of cardboard crafts seem good for learning.

https://cardbd.maruzonet.com/archives/1172?utm_source=chatgpt.com

I found some sites that might be helpful.

https://sagara-works.jp/research-and-development/cardboard-work/?utm_source=chatgpt.com

And the visual design version 2 has been completed.

step05: Design with Fusion 360

  • Keep sketching the designed parts.

The joint parts are set to be adjustable by parameters.

Of course, changing the parameters will change the joint parts. The image below shows a change in the thickness of the material itself from 5.18mm to 15.18mm to prove that it changes parametrically.

This time, the thickness of the material is 5.18mm, so I will correct it to the appropriate value.

What I learned from using Fusion 360 this time

  • There were moments when I wanted to adjust the sketch again after completing it. I got stuck not knowing how to do this. When I asked the instructor, Tamiya-san, I learned that adjustments can be made from the history below. I will remember each one.
  • I also learned that if I want to duplicate and process a sketch, it is good to use the project function.
    • According to the official documentation, the following description exists:
    • This YouTube video (in Japanese) was easy to understand
    • In other words, it is a function that allows you to project shapes from a certain position onto a plane. Projection can be done from a body to a plane or from one plane to another. Naturally, the shape will differ depending on the position from which it is projected, so caution is necessary.

step05: Cut out from the cutting board with a laser cutter

Using the following values discovered during group work.

Z-axis 0.00mm
Power 60%
Speed 10%

Please、See the Groupwork page for more details. https://fabacademy.org/2025/labs/kannai/Weekly_Group_Assignment/week03/

Step06: Assemble

  • Assemble the cut parts
  • It’s complete!

This stand has a path for the cable to be inserted below, allowing you to charge both the earphones and smartphone while keeping it on the stand.

  • And, surprisingly, it can also turn into a crab!

  • Instructor Tamiya was smiling wryly…

3. Consideration of ways to achieve the task more quickly and easily

  • This time I made multiple parts, but I feel like a similar stand could be made using just one part like LEGO. If so, I think I could have completed the cutting and assembly faster while ensuring greater expandability.

4. Receive feedback at region reviews

In the region review, I received feedback that my assignment may not meet the requirements.

Specifically, I received the following feedback:

Before it was very strict that the pressfit kit should be something like Lego that looks generic but can be put together to make other shapes. Neil always changes his mind every year, and depending on your global evaluator, what you have right now (the phone holder) is okay, but some evaluators might tell you to do it again or differently. So just watch out for that and make sure that your documentation shows that you have the knowledge of using parametric design when you made your phone holder.

I thought it would be fine as long as it could be assembled into different shapes, but considering the feedback, I understand that I may have misunderstood. I realized the importance of directly and clearly confirming with Neil during the lecture whether the assignment requirements align with my understanding. If the premise is different, everything changes.

Therefore, to meet this requirement, I plan to remake the pressfit kit on Saturday with the strict requirement that it must be something like Lego, looking generic, and able to be combined to create other shapes, and I will add this to the document.↓↓

5. Create another parametric modeling and cut it with a laser cutter.

The official Fusion 360 documentation states that patterns and quantities can also be changed.
https://www.autodesk.com/jp/support/technical/article/caas/sfdcarticles/sfdcarticles/JPN/How-to-create-a-Parametric-Formula-that-increases-a-pattern-in-Fusion.html

I think this video (in Japanese) will be helpful for parametric modeling. It changes the number of shelves from 1 to 88 with a single parameter.

Once the requirements were clear, all that remained was for me to create them. Thus, we have done the parametric modeling. This Saturday, we will cut it out with a laser cutter.

If the parameter is set to 1, there is one joint and one hole.

If the parameter is set to 2, the joint and the hole change to two.

I was able to create a parametric model. Yay!

I then cut this model from the material with a laser cutter and assembled it at a local session in Week04.

6. Cut the seal with a vinyl cutter and transfer the pattern by sandblasting.

I attempted to cut the seal using a vinyl cutter and transfer its pattern onto a three-dimensional object using sandblasting.

The tool I used was SILH-CURIO-2-J.

step01. Create the design.

I like using a web app called Canva, so I designed it there. Canva is a tool that allows you to design online. I prefer it because it has a rich variety of fonts, graphics, templates, and image editing features.

step02. Convert it to a dxf file.

I used this site for the conversion. https://products.aspose.app/imaging/ja/conversion/image-to-dxf#google_vignette

step03. Install the dedicated software.

The SILH-CURIO-2 requires dedicated software. You can download the software from the following site.

step03. Set up the SILH-CURIO-2, load the dxf file, and process the seal.

The settings are as shown on the screen.

Let’s set the seal in the machine. Normally, the seal is fixed to the machine by static electricity, but the force of fixation is weaker than we expected, so we will use masking tape to secure the seal to the machine.

step04. Prepare and conduct the test.

If there are no issues with the test, let’s proceed.

step05. Attach the cut seal and mask the areas that are not intended.

Attach the cut seal to the target you want to sandblast. This time, I chose a plastic piggy bank. My immediate goal is to become a little wealthy through fab academy savings! I was diligently masking, but I forgot to take a photo of this process.

step06. Sandblasting.

Perform the sandblasting. Since dust will fly, you can either wear a mask or choose not to breathe when placing the target inside the sandblasting machine. I didn’t have a mask, so I chose not to breathe. It’s been a long time since I held my breath like this, since playing in the pool.

The sandblasting is over in an instant. Holding the gun inside the machine with dedicated gloves, when you pull the trigger of the gun, sand is blown onto the target.

And there it is! * finish!

4. Download link

  • smartphone stand
    • svg and f3d files for creating smartphone stand can be downloaded together.
  • generic parametric model
    • svg and f3d files for creating generic parametric model can be downloaded together.
  • sand blast
    • svg and f3d files for creating sand blast can be downloaded together.

Tips

A simple way to transfer data between Android and Mac (Windows)

~~* When taking photos, I use Android, but I often do editing and processing on a PC. If the smartphone I am using is an iPhone, I can easily send data via AirDrop, but with Android, that function is not available. In such cases, Send Anywhere is convenient. You can easily transfer data directly between devices up to about 5GB.~~

~~ * https://send-anywhere.com/ ~~

Neal will update here with his advice. Smartphones and PCs can communicate via Bluetooth. Therefore, it would be easier to exchange images and videos via Bluetooth.