Group Assignment

1. Safety Rules for Laser and Vinyl Cutters

Team: Manuel Ayala-Chauvin, Sandra Nuñez-Torres
Institution: Fablab - Universidad Tecnológica Indoamérica
Year: 2025

3. Characterization of the Epilog FusionMaker Laser Cutter

FabLab Indoamérica

4. Laser Cutter Tolerance Test

FabLab Indoamérica

Individual Assignment

1. Vinyl Cutting Process

This section details the step-by-step process to cut and apply heat-transfer vinyl onto fabric using digital fabrication techniques. The process integrates design, machine setup, material handling, and transfer techniques using a heat press.

1.1. Design and Modeling in Illustrator

The design was created using vector shapes in Adobe Illustrator. The process involved:

• Using the rectangle tool to create modular components.
• Combining them using the Pathfinder tool to form a cross-based motif.
• Applying symmetry and alignment tools for consistent spacing.

1.2. File Export

The design was exported in a format compatible with the vinyl cutter:

• Save in JAPAN ILLUSTRATOR 3 format, compatible with the cutter.

1.3. File Import into Vinyl Cutting Software

The exported design file was imported into the vinyl cutting software provided by Roland. It’s important to:

• Mirror the image if working with heat-transfer vinyl.
• Verify alignment and scale before sending to the cutter.

1.4. Machine Configuration

The vinyl cutter was configured with the following settings:

• Blade force: 110 gf
• Cutting speed: 10 cm/s
• Blade type: 45-degree standard

1.5. Sending and Cutting

• Send the design to the machine and ensure the vinyl is correctly placed.
• Supervise the process for precise cuts.

1.6. Weeding and Heat Application

After cutting, the excess vinyl was removed manually ("weeding") to reveal the final design. The vinyl was then placed onto a white polyester fabric using the transparent carrier to position the design.

1.7. Heat Press Transfer

A heat press was used to transfer the vinyl onto the fabric. The settings used were:

• Temperature: 160°C
• Time: 15 seconds
• Medium pressure

After pressing, the carrier sheet was left to cool slightly before removal.

1.8. Removal and Application

The transparent carrier sheet was peeled off slowly, revealing a clean and durable finish on the fabric. The result was precise, with sharp edges and strong adhesion.

Summary

• This process can be applied to T-shirts, bags, and banners.
• Proper mirroring and cutting depth are critical for success.
• Pressing temperature and time must be adjusted according to the fabric and vinyl type.

2. kit Standard Modular Pieces for Configurable Structures

The image shows a set of laser-cut interlocking wooden pieces designed in a standardized modular format. These pieces can be assembled in various ways to create different 3D structures.

2.1. Modular Design Concept

• The pieces follow a uniform interlocking system, meaning each component has standardized slot widths and depths.
• They resemble cross-shaped connectors, allowing them to fit together in multiple orientations.
• The uniformity in dimensions enables scalability and expansion without the need for additional connectors.

2.2. Features of the Pieces

• Laser-Cut Precision: Ensures tight-fitting joints by compensating for kerf width.
• Symmetry: Allows multiple assembly possibilities without predefined constraints.
• Material: Likely MDF or plywood, chosen for its strength and ease of laser cutting.
• Edge Burn Marks: Indicate controlled cutting power for maintaining structural integrity.

2.3. Configurability and Possible Forms

These pieces can be used to construct:

• Geometric Shapes: Cubes, spheres, or irregular polyhedrons.
• Mechanical Structures: Frames for lightweight mechanical systems.
• Architectural Prototypes: Scaled-down modular buildings or conceptual frameworks.
• Artistic & Educational Models: Useful for hands-on learning and creative design exercises.

2.4. Advantages of This System

2.5 Design and Laser Cutting Process

1. Open SolidWorks: Select "File" → "New Part" → "2D Drawing".

2. Select Size: Configure the appropriate drawing size.

3. Create Sketch: Select the "Line" tool to start the sketch.

4. Draw the Piece: Create the 2D design with precise measurements.

5. Create Cutting Mesh: Prepare the design for the laser cutting process.

6. Export to PDF: Generate a PDF file of the final design.

7. Send to Machine Software: Upload the PDF file to the cutting machine software.


Laser Cutting Parameters Used

This section documents the calibrated laser cutting settings used for 3 mm MDF on the Epilog FusionMaker laser cutter. The goal was to achieve clean cuts with minimal burn marks and accurate fit.

• Material: MDF (Medium Density Fiberboard)
• Thickness: 3 mm
• Laser Cutter: Epilog FusionMaker (30W)
• Cutting Type: Vector cut
• Speed: 20%
• Power: 100%
• Frequency: 500 Hz
• Number of Passes: 1
• Focus Mode: Auto-focus enabled
• Air Assist: Enabled
• Ventilation: Extraction system ON

Kerf Compensation

The kerf (material lost to the laser beam) was measured at approximately 0.12 mm. This value was considered in the slot design to ensure tight but functional interlocking.

Calibration Process

• A power-speed test grid was performed on MDF with squares cut at various speed and power values.
• At 15% speed and 100% power: full cut with slight burn.
• At 25% speed and 90% power: incomplete cuts in denser grain areas.
• Final setting selected: 20% speed, 100% power, 500 Hz — produced clean, complete cuts.



These settings were calibrated through preliminary testing to minimize burning and ensure proper part separation without excess kerf loss. The results showed clean edges and consistent fit among components.

8. Execute the Cut: Start the laser cutting process on the chosen material.

9. Kit: Assembled parts kit.

2.6 Exploring Creative and Usable Forms with the Parametric Construction Kit

After cutting and assembling my parametric construction pieces, I explored their combinatorial potential through iterative physical prototyping. The results demonstrate that this kit can be used not only as an abstract modeling exercise but also to develop functional, playful, and modular structures.

Modular Assembly and Design Flexibility

The cross-shaped modules allow multi-directional connections, which unlocks vertical stacking and horizontal bridging. This makes the kit highly adaptable for toy design, interactive puzzles, or educational STEM tools.

Forming Usable Objects

From a few repeated elements, I was able to create:

• A freestanding character with legs and antennas (potential mascot or figurine)
• Interlocking rings and abstract animals
• Reconfigurable connectors that could serve as structural joints for small-scale mockups or design prototypes

Stability and Interaction

The burnt wooden edges from laser cutting also improve grip and friction between parts, avoiding slippage without glue or fasteners. This adds usability for design testing or classroom demonstrations.

Conclusion and Possibilities

This parametric construction kit is not just a conceptual model. It can evolve into:

• Puzzle kits for kids
• Educational STEM tools for explaining 3D geometry
• Miniature mockup components for architectural or product ideation

The creative potential grows with the scale and thickness variation, and it’s replicable using different materials such as acrylic, MDF, or cardboard.

2.6. Potential Improvements

• Adjustments for Tolerances: Fine-tuning the slot width to account for kerf variations in different materials.
• Different Thicknesses: Testing with acrylic or thicker wood for added durability.
• Integration with Other Materials: Combining with 3D-printed or metal parts for hybrid structures.