Wildcard Week
Metal Cutting Adventure
This week was Wildcard Week, which meant we could try out any digital fabrication process that we hadn’t already done in the other assignments. It was a super open-ended week, and I saw it as a chance to explore something I’d never worked with before — metal cutting! I chose to experiment with laser cutting and water jet cutting on metal.
Honestly, I’ve mostly worked with materials like wood, acrylic, and paper so far, so working with metal felt both exciting and a bit intimidating. I was really curious to see how digital fabrication works with tougher materials, and how accurate and clean the results can be when using these heavy-duty machines.
I started by designing a part specifically for metal — something that made sense to make from a strong material. Then I prepared the files in CAD and got help setting up the machine. Watching the laser and water jet cut through the metal was honestly quite satisfying.It ended up being one of the most hands-on, inspiring, and surprising weeks I’ve had.
Into the Streets of Byculla
I started my exploration by heading to Byculla, a place I had only heard about but never visited for fabrication work. The streets there are like a living manufacturing encyclopedia. Tiny workshops lined both sides—metal bending units, laser cutters, glass cutting, welding—all squeezed into narrow, noisy lanes full of sparks, heat, and movement. It felt chaotic but alive. Being in that environment was a whole experience in itself—it made me appreciate the energy and craft that goes into manufacturing at such small but powerful scales.
Metal Laser Cutting
Cutting out Name
the machine used for this was a fiber laser cutting machine—commonly found in industrial shops and great for fine detailing on thin metal sheets. The operator set the machine to trace the path at high speed, using focused laser light to slice through the metal with precision
Designing the File
I used Adobe Illustrator for designing both the nameplate and the kirigami structure.
For the nameplate, I typed my name in a clean Devanagari font and converted it into vector outlines using “Create Outlines”.
Exporting the File
After the design was ready
exported it as a DXF file (.dxf) because most industrial laser machines prefer this format.
I also saved a backup .svg and .pdf just in case the machine operator needed other versions.
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Adjusted the laser power and speed settings according to material (0.8 mm stainless steel)
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Placed the metal sheet on the bed, aligned it, and did a test run to check for alignment
-The operator imported my DXF file into their software (usually something like RDWorks or similar)
Laser Cutting
The fiber laser started cutting—an intense light beam followed my design lines and sliced through the metal sheet.
The cutting speed and laser intensity were tuned to avoid burn marks.
The process took about 1–2 minutes per piece.
Post-Processing
After cutting:
cleaned the edges with fine sandpaper to remove burrs
Kirigami on Metal
Feeling motivated, I decided to try kirigami—but not on paper. On metal. Kirigami is usually about folding and cutting a sheet to create 3D forms. I was curious if this technique would work with something so rigid. So, I designed a simple fold-based pattern in Illustrator and sent it for laser cutting again.
Here’s where I hit my first constraint: half cuts weren’t possible on this metal sheet or with this machine. The metal was too thick (0.8 mm), and the shop could only do full-depth cuts. So instead, I manually folded along the crease lines after cutting.
It wasn’t smooth or easy—metal doesn’t fold like paper. But with a bit of force and care, I made it work. The final form had this raw, mechanical look that I actually liked. It turned out to be a kind of industrial kirigami—not delicate, but still expressive in its own way.
Water Jet cutting
This process was completely new to me, and was genuinely shocked that water could cut through something as strong as metal.
The last and most mind-blowing part of this week was trying water jet cutting. I had only seen it online before and didn’t think I’d actually get to use one. The idea that a stream of high-pressure water mixed with abrasives could cut through solid metal felt unreal.
I learned a lot just by asking questions at the shop:
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The machine requires a minimum pressure of 5 tons
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It can cut through materials up to 30 cm thick
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It runs using an external generator and doesn’t burn or melt the material Designing the File
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used Adobe Illustrator, but this time to design a wall-mounted key hook with abstract shapes.
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avoided sharp internal corners and too-fine details because water jet cutting has a slightly wider kerf (cut width) than laser cutting.
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converted the design into vector paths and saved it as a DXF file.Designing form resembling Lion's face
Understanding the Machine Setup
The shop had a high-pressure abrasive water jet cutting machine. Here’s what I learned:
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It uses a jet of water mixed with abrasive particles (like garnet)
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Requires a minimum pressure of 5 tons
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It can cut through metal up to 30 cm thick
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It needs a separate generator and a huge amount of water to run
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The nozzle size determines how tight the corners can be
To test it out, I designed a small, abstract key holder shaped like a hook. Watching the water jet machine work was like watching sci-fi. The cut was precise, no burn marks, just a clean, smooth edge. It felt like working with nature and power at the same time.
Setting Up the Cut At the shop:
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DXF file was imported into their CAM software (often something like FlowPath or IGEMS)
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They placed a 3 mm thick mild steel sheet on the bed
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The nozzle path was simulated first to make sure it wouldn't collide or go off
Hero Shot
Water Jet Cutting Process
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The machine fired up and I watched the high-pressure stream slice through the metal slowly but cleanly.
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The cut wasn’t super fast, but it was extremely accurate.
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The best part? No heat marks or deformation, unlike laser cutting.
Cleaning and Finishing
After cutting:
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The part was rinsed and dried
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Burrs were minimal but I used sandpaper to smooth out the edges
Learned
This week was a huge learning curve—not just about machines, but about materials, environments, and the kind of thinking digital fabrication demands.
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With laser cutting, I had to plan around material thickness and the limitations of the machine (like no partial cuts).
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Kirigami in metal taught me that techniques don’t always transfer directly across materials—they need to be rethought.
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Water jet cutting gave me new respect for material versatility and industrial power.
Reflection
Looking back, this wasn’t just a week of experimenting with machines—it was about stepping into a new world, full of noise, sparks, and steam. From seeing my name in steel, to folding metal like paper, to slicing it with water—this week reminded me why I love designing and making. Every material behaves differently, every technique demands its own logic, and there’s always something magical when you see your idea become real.
Problems Faced & Solutions
1.Half-Cuts Not Possible for Kirigami
The idea was to try kirigami-style folding on a metal sheet, but the fiber laser cutter couldn't do partial-depth cuts—only full cuts. This made clean folding tricky.
Solution:
Full cuts were used instead, and the folds were manually done using pliers and a flat surface. The bends weren't machine-precise but worked well enough for a test. A thinner sheet or CNC bending could help next time.
2.Sharp Edges and Burn Marks After Laser Cutting
Post-cut, the metal had sharp edges and some surface discoloration, especially on detailed parts like the Devanagari text.
Solution:
Edges were cleaned using fine sandpaper. It's something to keep in mind for future metal work—laser cutting often needs a bit of finishing afterward.
3.Water Jet Cutting Access and Limitations
Water jet cutting wasn’t as accessible. The setup required time, and the cost made it hard to test small changes or do multiple trials.
Solution:
A compact, sturdy design was chosen—an abstract hook key holder that didn’t risk material wastage. Clean lines and no overly thin sections made it easier to get it cut in one go.
4.Unfamiliarity with Machine Capabilities
At first, it wasn’t clear how much spacing to leave, how wide the kerf would be, or how much detail the machines could handle.
Solution:
Started with a basic nameplate design to observe the results. Discussions with machine operators helped clarify limitations. Future designs will include more consideration for material thickness, kerf, and cut complexity.