- Group Assignment
- Do your lab's safety training
- Characterize our lasercutter's
- Individual Assignment
- Cut something on the vinyl cutter
- Design, lasercut, and document a parametric construction kit:
- Accounting for the lasercutter kerf
- Which can be assembled in multiple ways
- For extra credit, include elements that aren't flat
Week 3: Computer controlled cutting
Group Assignment
1. Safety Rules for Laser and Vinyl Cutters
FabLab Indoamérica
1.1 General Safety Guidelines
- Only trained and authorized personnel may operate the machines.
- Personal protective equipment (PPE) must be worn when necessary (e.g., safety glasses for the laser cutter).
- Machines should never be operated without supervision.
- Keep the workspace clean and free of flammable objects.
- Ensure ventilation and smoke extraction systems are active before operating the laser cutter.
1.2 Laser Cutter (Epilog FusionMaker) Safety Rules
1.2.1 Before Operation
- Ensure the material is laser-compatible and does not release toxic fumes.
- Check that the laser optics (mirrors and lenses) are clean.
- Set power, speed, and frequency according to the material specifications.
- Close the machine’s lid properly before starting the cut.
1.2.2 During Operation
- Never leave the machine unattended while running.
- Watch the process through the safety window without opening the lid.
- In case of fire, stop the machine immediately and use the lab fire extinguisher.
1.2.3 After Operation
- Wait for the cut pieces to cool before handling.
- Clean any debris from the cutting area.
- Turn off the machine and disconnect it if not in use for an extended period.
2. Vinyl Cutter (Roland) Safety Rules
2.1 Before Operation
- Ensure the blade is properly adjusted and in good condition.
- Set the correct pressure and speed based on the material.
- Align and secure the vinyl properly in the machine.
2.2 During Operation
- Keep hands away from the cutting head while the machine is running.
- Supervise the process to prevent material misalignment or blade damage.
- Stop the machine immediately if an issue occurs.
2.3 After Operation
- Carefully remove the cut material and clean the workspace.
- Turn off the machine when not in use.
- Store blades and tools properly after use.
2.4 Emergency Procedures
- In case of fire, use the CO₂ extinguisher available in the FabLab.
- Report any incidents or machine malfunctions to the FabLab supervisor.
- Follow first aid protocols and contact lab personnel if an injury occurs.
3. Characterization of the Epilog FusionMaker Laser Cutter
FabLab Indoamérica
3.1 General Information
- Brand & Model: Epilog FusionMaker
- Type: CO₂ Laser Cutter
- Functionality: Precision cutting and engraving
- Common Uses: Prototyping, fabrication, artistic engraving, industrial applications
3.2 Technical Specifications
- Laser Type: CO₂ laser
- Power: 30W, 40W, or 50W options
- Work Area: Approx. 24” x 12” (609 mm x 305 mm)
- Resolution: Up to 1200 DPI
- Speed & Power Control: Adjustable settings
3.3 Supported Materials
3.3.1 Cutting Capabilities
- Wood (MDF, plywood, etc.)
- Acrylic
- Leather
- Cardboard
- Fabric
- Some plastics (Non-PVC)
3.3.2 Engraving Capabilities
- Glass
- Ceramic
- Coated metals
Prohibited Materials: PVC, polycarbonate, and materials that release toxic fumes.
3.4 Key Features
- Enclosure: Fully enclosed system with a transparent lid
- Ventilation System: Integrated air exhaust
- Control Panel: Digital interface
- Air Assist: Reduces flaming and improves precision
- Red Dot Pointer: Previews the cutting area
3.5 Laser Calibration Grid
Displayed in the first image, the power vs. speed test grid is used to determine optimal settings for different materials.
- Power settings range from 10% to 100%
- Speed settings range from 10% to 100%
- The darker the engraving, the more material was removed
3.6 Safety Considerations
- Protective Gear: Safety glasses for reflective materials
- Machine Supervision: Never leave unattended
- Fire Prevention:
- Keep a CO₂ fire extinguisher nearby
- Avoid highly flammable materials
- Ensure proper ventilation
- Cleanliness: Regular maintenance to prevent overheating
4. Laser Cutter Tolerance Test
FabLab Indoamérica
4.1 Objective
This experiment aims to determine the optimal fit for interlocking laser-cut pieces by testing different slot widths and evaluating tolerances.
4.2 Methodology
- Material: Medium-density fiberboard (MDF) or plywood.
- Laser Cutter Used: Epilog FusionMaker.
- Slot Widths Tested: Ranging from 2.9 cm to 3.6 cm in 0.1 cm increments.
- Kerf Consideration: Adjustments were made to account for material removal by the laser.
- Laser Settings: Power, speed, and frequency optimized for minimal burning and clean cuts.
4.3 Observations
- Tighter Fits: Slots between 2.9 cm - 3.2 cm required force for assembly.
- Looser Fits: Slots between 3.4 cm - 3.6 cm allowed for easy but potentially unstable connections.
- Optimal Fit: Likely within the 3.2 cm - 3.3 cm range.
- Burn Marks: Indicating laser power may be slightly high or multiple passes were used.
4.4 Adjustments for Future Tests
- Refining kerf compensation based on precise measurements.
- Optimizing laser power and speed to reduce burns.
- Testing different materials like acrylic and plywood for comparison.
- Evaluating mechanical strength of each fit under load conditions.
4.5 Conclusion
This test is essential for achieving precise fits in interlocking structures such as furniture, enclosures, and mechanical joints. Adjusting design files based on these results ensures accurate assembly and functional strength.
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
- Blade force: 110 gf
- Cutting speed: 10 cm/s
- Blade type: 45-degree standard
The vinyl cutter was configured with the following settings:
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
- Reusability – Components can be disassembled and reassembled into new configurations.
- Expandability – The modular nature allows for additional pieces to be integrated easily.
- Parametric Design – This system can be adapted for larger-scale projects by adjusting the slot dimensions.
- Efficient Manufacturing – Minimal material waste and easy mass production using a laser cutter.
2.5 Design and Laser Cutting Process
- Open SolidWorks: Select "File" → "New Part" → "2D Drawing".
- Select Size: Configure the appropriate drawing size.
- Create Sketch: Select the "Line" tool to start the sketch.
- Draw the Piece: Create the 2D design with precise measurements.
- Create Cutting Mesh: Prepare the design for the laser cutting process.
- Export to PDF: Generate a PDF file of the final design.
- Send to Machine Software: Upload the PDF file to the cutting machine software.
- Execute the Cut: Start the laser cutting process on the chosen material.
- 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.
Week 3: Conclusion
This week focused on computer-controlled cutting, exploring the precision and versatility of laser and vinyl cutting techniques. The hands-on experience with laser cutting included characterizing kerf widths, optimizing material selection, and understanding safety protocols. Additionally, the individual assignment reinforced parametric design principles through modular construction, allowing for flexible and scalable configurations. The week provided valuable insights into digital fabrication processes and their applications in engineering, design, and rapid prototyping.
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