Week 3 : Computer Controlled Cutting

Objectives of the Week

Design, lasercut, and document a parametric construction kit, accounting for the lasercutter kerf, which can be assembled in multiple ways. Cut something on the vinyl cutter

Group Assignment

For more About Group Assignments

Kerf Measurement

Procedure

Designing a 100 mm × 100 mm square using the optimal parameters.

Using LaserCAD software for sending the design to the Laser machine

Cutting Designed files for measurement

Measuring the Files for the Kerf Measurement in both MDF and Acrylic materials

Measured slot width using a vernier caliper.

Measured both cut piece and remaining slot using a vernier caliper.

Calculated kerf = (slot width – piece width) / 2.

Results

Material	Designed Size	Measured Slot (mm)	Measured Piece (mm)	Kerf (mm)
MDF	100 × 100	100.30	99.70	0.30
Acrylic	100 × 100	100.25	99.75	0.25

Parametric Lamp Design Kit

For the Paramaetic Lamp design I have refered this video

2D laser-cuttable design with customizable dimensions

I planned to design the lamp in three strucutres one is that, The Connectors Which I done Initial design in 2D drafting and then designing the base plate which connecting all the hands and then conecting the hands to the base plate

Parametric Design in Fusion 360

Parametric design in Fusion 360 involves creating models where key dimensions and parameters drive the geometry. This approach allows for easy modifications and fine-tuning, as changes to the parameters automatically update the entire model.

Defining Parameters: Parameters are defined at the start, such as the length, width, or diameter. These parameters can be used throughout the design to maintain consistency and allow for quick adjustments.
Using Constraints: Constraints are used to maintain relationships between different parts of the model. For example, ensuring that two lines remain parallel or that a circle stays concentric with another shape.
Advantages: Parametric design allows for efficient iteration, as changes can be made quickly by altering parameter values. This is particularly useful for prototyping and testing different design configurations.
Example: When designing a lamp in Fusion 360, you can set parameters for the lamp's height, base diameter, and connector thickness. Adjusting these parameters will automatically resize and redefine the lamp's components, providing flexibility in design exploration.

By leveraging parametric design, designers can create adaptable and scalable models that meet specific requirements and constraints.

For the Parametric Design

I Initially fixed a Dimension of d5 to the common for all dimensions

Next I have taken the same value for the Hands Design to and then changed its value too

Similarly I have used this for all of my areas where I am Connecting one with Each other

Hand Design

Initially I considered all the aspects and then having the edges of the connectors as 4mm and as there two connectors will be have and I assigned the 4mm as both ends as a parametric.

Base Plate Design

And then considering the common 4mm connectors as parametric constraint for the base plate cuts

As we have to connect the hands to the base plate, so I used the same parametric as the connector, which is 4mm.

Intial parameters

I have done the initial parametric design in Fusion 360 and the below listed are the initial parameters that came along with the design

Now what I am going to do is chaning the inital design that I have done in Fusion 360, Initially I have taken a d5 as my Initially measuring thing

Initally you can see here the design is much more what we initially had, Now I going to change that value from 40mm to 20 mm, Let's see how its affecting the design

Hero Shot

LaserCAD

Laser Cutting Guide

Recommended Settings:

Material	Speed	Power
3mm Plywood	8mm/s	85%
6mm Plywood	5mm/s	90%

Cut interior features first, then outer contours

Assembly Steps

Connect base components
Insert vertical supports
Attach shade panels

Hero Shot

Viny Cutting

For this week's computer-controlled cutting assignment, I made a personalized vinyl sticker with my name "MUHESH | FAB LAB MADURAI". The goal was to understand the full workflow of designing, preparing, cutting, and transferring vinyl using a SkyCut C24 machine along with the SignMaster software suite, which includes the Vinyl Spooler, where the actual cutting job is processed.

This documentation explains each step in detail, from digital design to final application.

Design Process

Choosing the Design Software

I used a vector-based design tool (Inkscape / Illustrator / CorelDRAW)
Vinyl cutters require vector paths, so the design must be created using scalable vector graphics

Creating Text for the Sticker

I created the following text:
- MUHESH
- FAB LAB MADURAI
I used a bold, easy-to-weed font to ensure smooth cutting and clean readability

Converting Text to Vector Paths

Since vinyl cutters cannot interpret text formats:

I converted the text to paths/outlines/curves
This prevents font errors and ensures clean blade tracing

Final Design Dimensions

I scaled the design to the desired size:
- Width: ~14.93 cm
- Height: ~8.3 cm
This ensures easy weeding and efficient material usage

Exporting the File

To prepare the file for cutting, I exported it as:
- SVG (recommended)
The SVG file was then imported into SignMaster

Sign Master

Sign Master is a software used to create and customize vinyl cutting designs. It is a free software that can be downloaded online. This software allows the user to create their own designs or modify existing ones. It also provides a variety of tools and features to help the user to create their design.

Create and customize vinyl cutting designs
Modify existing designs
Provides a variety of tools and features

Using SignMaster for Vinyl Cutting

Importing the Design into SignMaster

I opened SignMaster and chose:
- File → Import → (Select SVG file)
The design loaded into the workspace where I could verify:
- Dimensions
- Alignment
- Path accuracy

Sending the Job to Vinyl Spooler

SignMaster uses a built-in tool called Vinyl Spooler to communicate with the SkyCut machine
I clicked:
- Cut → Send to Cutter (Vinyl Spooler)
This opened the Vinyl Spooler window

Job Preview in Vinyl Spooler

In Vinyl Spooler, I checked:

Correct orientation
Path preview
Cutting boundaries
Actual size (14.93 cm × 8.3 cm)
Selected cutter: SkyCut C24

This step ensures that the vinyl will be cut accurately.

Machine Settings in Vinyl Spooler

In the Cut Options tab, I configured:

Parameter	Setting
Speed	300 mm/s
Force/Pressure	120–150 g
Mode	Cutting/Contour Cut
Passes	1
Blade	45° blade

These settings are ideal for thin-to-medium vinyl.

I also used the Test Cut option to verify the blade depth.

Preparing the Vinyl Material

Selecting Vinyl Sheet

I used standard adhesive vinyl:
- Top: colored vinyl
- Middle: adhesive layer
- Back: paper backing sheet

Cutting the Vinyl to Size

I cut a piece slightly larger than my design area to allow margin for alignment and origin setting

Checking the Vinyl Surface

Before loading:

Ensured the sheet was flat
Checked for dust or wrinkles
Confirmed backing paper was intact

This ensures smooth feeding inside the cutter.

Loading Vinyl into the SkyCut C24

Aligning and Securing the Material

Steps:

Lifted pinch rollers
Inserted vinyl sheet
Aligned it parallel to the machine guide
Positioned pinch rollers over the grit wheels
Locked them in place

Proper alignment prevents shifting during cutting.

Setting the Origin

Using the machine controls, I positioned the blade at the lower-left corner and pressed:
Set Origin
This tells the machine exactly where to start cutting

Cutting the Vinyl

Executing the Cutting Job

Back in Vinyl Spooler, I clicked Cut Now
The SkyCut C24 began cutting the sticker precisely following the vector paths
During the process, I monitored:
- Material feed
- Blade movement
- Any lifting or tearing

Weeding the Vinyl

Removing Excess Vinyl

Using a weeding tool or tweezer:
- I peeled away the unwanted outer vinyl
- Removed internal pieces inside letters (A, R, B, D, etc.)
Weeding requires patience, especially for small text

Inspecting the Results

After weeding, I checked:

Cleanly cut edges
No tears
All letters intact
Proper spacing maintained

Applying Transfer Tape

Preparing the Tape

I cut a transfer tape piece slightly larger than the sticker

Applying the Tape Over the Vinyl

Steps:

Placed tape over the weeded design
Pressed it firmly using a squeegee
Ensured bubble-free adhesion

The tape helps lift the design cleanly for application.

Lifting the Sticker

I slowly peeled the tape, ensuring the vinyl letters stuck to it completely

Applying the Final Sticker

Preparing the Target Surface

I cleaned the surface using a dry cloth and ensured it was dust-free

Transferring the Vinyl

Steps:

Placed the tape (with vinyl) on the target surface
Reseated it with a squeegee
Slowly peeled away the transfer tape
The vinyl lettering remained cleanly on the surface, forming the final sticker

Final Output

The final vinyl sticker: "MUHESH R"
was successfully cut, weeded, and applied.
It has sharp edges, proper alignment, and professional finish.

Download the files

You can download the encoded model by clicking on the following links.