Assignment Brief:

1. Understanding formats: Characterize your lasercutter's focus, power, speed, rate, kerf, joint clearance, and types.
2. Laser cutting: Design, lasercut, and document a parametric construction kit, consideration of lasercutter kerf and assembly in multiple configurations.
3. Vinyl cutter: Cut a design using the vinyl cutter and try to explore its process and application.

Understanding Formats:

To begin with the fundamentals, the laser cutter I worked on and studied was from the Riidl FabLab lasercutter: CO2 Laser cutter from SIL (Suresh Indu Lasers Pvt. Ltd). Learn about the laser cutter Company: Suresh Indu Lasers For better understanding of lasercutter at Riidl- The Standard Operating Procedure (SOP) for Riidl lab as a pdf: Riidl Laser Cutter SOP (PDF)

CO2 Laser cutter from SIL (Suresh Indu Lasers).

Types of Laser cutter

A laser cutter is a machine that uses a high-powered laser beam to cut, engrave, or mark materials with precision. The laser generates intense heat to vaporize, burn, or melt the material, creating clean and accurate cuts. Laser cutters come in different types based on the laser source they use. I reffered to ChatGPT to understand The three main types of Laser cutters are:

CO₂ Laser Cutter:
• Best for: Cutting and engraving non-metal materials like wood, acrylic, paper, fabric, and leather.
• How it works: Uses a gas mixture (mainly carbon dioxide) excited by electricity between anode and cathode to produce a laser beam.
• Power range: 30W to 400W (common in commercial use).(In laser cutters, power (measured in watts, W) refers to the energy output of the laser beam. It determines how effectively the laser can cut or engrave materials.)
• Pros: Affordable, high precision, works well on organic materials.
• Cons: Not effective for cutting most metals without additional modifications.

Fiber Laser Cutter:
• Best for: Cutting and engraving metals (steel, aluminum, brass, copper) and some plastics.
• How it works: Uses a fiber-optic cable to amplify light, creating a powerful and concentrated laser beam.
• Power range: 500W to 12,000W (industrial applications).
• Pros: High efficiency, long lifespan, minimal maintenance.
• Cons: More expensive than CO₂ lasers, not ideal for organic materials.

Diode Laser Cutter:
• Best for: Engraving on wood, plastics, leather, and some metals (with coatings).
• How it works: Uses semiconductor diodes to generate a laser beam.
• Power range: 1W to 15W (for hobbyists and low-power applications).
• Pros: Compact, affordable, energy-efficient.
• Cons: Low power, slow cutting speed, limited material compatibility.

To learn more about laser cutters and their type refer to my research. ChatGPT The Laser cutter that we use in Riidl FabLab is the Co2 Laser cutter. Now lets understand the Safety Precaution, Focus and Kerf of this laser cutter. I understood the safety precautions of the machine alsong with the my Fab Academy friends: Sharvari Akerkar, Mihir Shah, Sohan Suryavanshi and Devanshi Mengar. Further, I calculated the kerf and focus of the laser cutter as a group activity along with my friend Sharvari Akerkar

Laser Cutter Safety Measures

Laser cutting safety measures prevent accidents, protect users, and ensure efficient operation. Proper ventilation removes toxic fumes, reducing health risks. PPE, like UV safety glasses and fitted clothing, shields against burns and laser exposure. Correct material handling and laser settings prevent hazardous emissions and overheating. Fire safety and workspace organization minimize risks, ensuring precision and smooth workflow.

Ventilation: Ensure proper airflow or use an exhaust system to remove fumes.

Material Handling: Check MSDS; avoid hazardous materials like PVC.

Settings: Adjust power, speed, and focus for clean cuts and safety.

Fire Safety: Keep a fire extinguisher nearby; never leave unattended.

Workspace: Keep the area clutter-free; close the enclosure and clean waste regularly.

Laser cutter Working

At the rear, a CO₂-filled glass tube generates a laser beam when electrified. The beam travels via mirrors to the cutting head, where a lens focuses it for precise cutting and engraving. The key Components of the Lazer cutter are: 1. Cooling System: Circulates water around the tube to prevent overheating. 2. Exhaust System: Uses a fan to remove smoke and fumes, ensuring ventilation. 3. Laser Bed (3 × 4 ft): Holds materials; must be level for accuracy, checked using a spirit level.

Lens of the cutting head focusing laser beam.



Spirit level to check if the bed is straight

Focus

In a laser cutting machine, focus refers to how precisely the laser beam is concentrated on the material. The focal point is the spot where the laser beam is at its smallest and most intense, providing the best cutting or engraving results. The focus is important for cutting precision, efficiency, material thickness handling and edge quality.

Focus is controlled by adjusting the laser head height and the focal lens position. The process by which we calculated the focus is as follows:

Firstly, I would like to mention here that my Fab Lab instructor Pranav Gawde , gave us an assignment to think of ways we could calculate the focus. On pondering about the same, I thought 1. We could change the bed height, but the bed size movement is not precise. 2. We could build a staircase like structure with a millimeter step distance, but the complexity of the step design increase, plus the precision of decimals is lost. 3. Finally, creating a slope, held on a hypotenuse triangle at an angle of 45 degrees, this would help us give the precision of the focus. I also reffered to my fab instructor's page, Jesal Mehta. Instead of using an scalene triangle he used the 30-60-90 degrees triangle, thus the focus length would be half thinnest line on the slope.

Note: For my focus calculation tests, I used MDF as the material to determine the optimal laser settings. Additionally, for my kerf analysis and parametric design, I utilized a 3mm acrylic sheet that was available as an unused piece in the Fab Lab. This allowed me to experiment with precision cutting and adjust my design parameters accordingly, ensuring efficient material usage while refining the accuracy of my laser-cut components.

Triangle Slope Design. 10*15*15



Triangle Slope Cut.



Triangle Slope.

Once the device for calculating the kerf was created, we were all ready to calculate our focus. 1. We adjusted the bed height to for the laser nozzle to touch the height tip of our triangle and with the precise power and speed of laser cutter as per the 2mm mdf material that is: (Power-80, Speed-8), we drew a straight line throughtout the slope. On calculating from the start point of the kerf to the the thinnest portion of the line we got the focus at about a distance of 5mm. However, we were a bit skeptical on deciding if its 5mm/4mm. Thus we performed test number 2. we drew horizontal straight lines throughtout the slope at a distance of 1mm each, on laser cutting this design we found our focus to be 5mm precise.

Horizontal Lines Design



Learning 1.

Focus length line number: 5mm

Include the nozzle radius in the focal length calculation of the laser cutter to account for beam convergence and precision. Adjust the formula accordingly to ensure accurate focusing. We calculated the nozzle radius affecting the focus precision.

Nozzle diameter= 5mm, radius= 2.5mm



calculating focus

Final Focus Length= 6mm

Kerf

Kerf refers to the width of the material removed by the laser beam during cutting. It is the gap left between the cut edges and depends on factors like laser type, power, material properties, and focus settings. The focus is important for Precision in design (eg. while building mechanical joints), Material Waste, material thickness and Cut Quality.

The factors affecting kerf are:

Laser Type & Power – Higher power lasers create wider kerfs due to increased heat dispersion.

Material Type & Thickness – Soft materials (wood, acrylic) have a larger kerf and hard materials (metal) have a smaller kerf but require more power.

Focus & Beam Diameter – A well-focused laser produces a narrower kerf and vice-versa. Therefore, we performed the Focus test before the kerf test.

Cutting Speed – Faster speed → Narrower kerf. Slower speed → Wider kerf (more material burns away).

Calculating kerf, I call it the comb cut: To calculate the kerf using a comb-like mechanism,I start by creating a rectangular design file with evenly spaced line slots, each set 1 mm apart. I used Fusion 360 software to ensure precision with the measurements. Once the file was ready,I laser cut it using a controlled speed of 10 and a power setting between 60 and 80, ensuring consistency in material removal. After cutting, measure the actual distances between the slots using a vernier caliper.Finally, I Compared these measurements with the original design to determine the margin of error, which represents the kerf width. This process helps in calibrating the laser cutter for future projects requiring precise fits. Other ways of calculating the kerf is laser diameter/2.

Designing the Comb



Laser cutting the comb, by cuttting on the precise focus that we calulated above.



Using Vernier caliper to calculate.

Final Kerf Length= 0.09mm

Joints

Building Joints: By accounting for the measured kerf, I worked on designing and building joints. Accounting for kerf ensures a precise, tight-fitting connection, reducing gaps and enhancing structural integrity. Proper kerf compensation prevents loose joints that may weaken over time or overly tight joints that can cause material stress. This precision improves both the durability and aesthetics of the final assembly.

Here I am learning and understanding different joints and their tolerance to kerf.

Press-fit – A tight-fitting joint where friction holds the pieces together without adhesives or fasteners.

Chamfer – A beveled edge is added to ease assembly and reduce stress concentrations in press-fit joints.

Snap-fit – Uses flexible features like hooks or clips that snap into place to create a secure but removable connection.

Flexure – A compliant mechanism that allows bending or flexing to enable assembly or movement.

Pinned – Uses a pin or dowel to provide rotation or a secure locking mechanism between parts.

Finger – Interlocking tabs and slots that increase joint strength, often used in woodworking or laser-cut assemblies.

Snap – A locking mechanism where parts snap together with built-in retaining features for easy assembly.

Wedge – Uses a tapered design to secure parts by applying force, increasing friction for a tight hold.

Joints



Analyzing Kerf and building joints

Chamfer joint: I worked on the Chamfer Joint, The chamfer joint is beneficial as it provides a larger surface area for adhesion, improving joint strength. It enhances aesthetics by creating smooth transitions between edges, reducing sharp corners. This joint also helps in better stress distribution, minimizing material fatigue over time. Additionally, it allows for precise alignment, ensuring a cleaner and more professional finish in assembled structures.

Error I made: This error stemmed from either haste or time anxiety, leading to an incorrect kerf calculation for the chamfer joint. Initially, I miscalculated by applying the kerf of each slot relative to the other, resulting in a loose fit. Realizing the mistake, I corrected it by applying the material kerf properly—deducting 0.1mm from each slot in a 3mm plywood, making the final slot measurement 2.90mm. This adjustment ensured a precise, tighter fit for the joint. However, this error helped me learn the types of fit:

Interference fit: Tight assembly

Clearance fit: Precise assembly

Loose fit: Loose assembly.

Calculating the material thickness to build the slot of my Chamfer joint.



Trial and errors of the interferance, loose , clearance fit by experimenting the value of kerf.



Precise final fit was 0.09, which was precise to my kerf calculation above.

Parametric design

Parametric design is a process that uses algorithms and computational techniques to generate and manipulate complex designs based on a set of parameters and rules. Instead of manually defining every aspect of a design, you set parameters (like dimensions, angles, curves, or materials), and the system automatically updates the design when changes are made. Changes in one part of the model update all related parts automatically.It provides efficiency & flexibility so designers can experiment with multiple variations quickly. Keeping in mind the kerf valaue, material thickness and the chamfer joints precision, I set on making parametric design. Drawing inspiration from one of my favorite designers, Paul Cocksedge , I explored fluid, functional, and interactive design elements.

The work, designed as a place to sit or play, frames views of the district’s architecture within frames.



PUSH TOWER WIP: Push once for the body, two is for shade, three is for the elements and the fourth one to be for the birds.

This inspired me to make an attempt of a speculation, to build a miniature scaled version of a live size model.I attempted a parametric design of a swastik: Indian Religious symbol, evolving into a 3 by 4 swastik, as part of my exploration to create an artistic seating and bird feeder installation for public spaces. This concept merges cultural symbolism, functionality, and nature interaction, providing a space for both people and birds/ billboard which I describe below. Through CAD modeling and prototyping, I explored modular adaptability, ergonomic seating, and integrated feeding spaces, considering form suitabability for urban environments. This model represents my initial attempt at developing a public installation that encourages social engagement and coexistence with nature.

My Parametric Design:

Vinyl Cutter

To begin with the fundamentals, the Vinyl cutter I worked on and studied was from the Riidl FabLab Vinyl Cutter- GRAPHTEC Cutting Plotter CE7000. For better undertanding of the vinyl cutter refer to the Standard Operating Procedure (SOP) for Riidl lab Vinyl cutter as a pdf: Riidl Laser Cutter SOP (PDF)

Difference between vinyl cutter and laser cutter: Unlike laser cutting, which burns through materials, a vinyl cutter uses a sharp blade to slice through thin films with extreme accuracy. This makes it ideal for cutting materials like adhesive vinyl, heat transfer vinyl, and thin foils without causing heat damage or charring. Since the process is entirely mechanical, it ensures clean, precise edges without any discoloration, making it perfect for applications like stickers, decals, and intricate signage. Additionally, vinyl cutters are more efficient for handling flexible and delicate materials that might otherwise warp or melt under the high temperatures of a laser cutter

The Graphtec Cutting Plotter CE7000 is a high-precision vinyl cutter used for cutting stickers, decals, labels, and heat transfer materials. It has Advanced Cutting Precision supporting contour cutting with high accuracy. Also, it has advanced connectivity with USB, Ethernet, and barcode support for automated cutting. It has media compatibility with various materials, including

Vinyl: A flexible, adhesive-backed material used for signage, stickers, and labels. Example: Wall decals, laptop stickers.

Outdoor Vinyl Weather-resistant vinyl designed for long-term outdoor use, often UV-resistant and waterproof. Example: Storefront signage, car decals, outdoor banners.

Clear Film: Transparent vinyl used for overlays, window decals, and see-through stickers. Example: Glass door branding, clear labels on bottles.

Reflective Film: Contains tiny glass beads or prisms that reflect light, making it highly visible at night. Example: Road signs, emergency vehicle decals.

Fluorescent Vinyl: Bright, neon-colored vinyl that enhances visibility, especially in low light. Example: Safety signage, high-visibility stickers.

Car Film: Specialized vinyl used for vehicle wrapping, available in glossy, matte, or textured finishes. Example: Full-body car wraps, racing stripes, paint protection film.

Thick Substrate: Rigid or thick materials that require higher cutting force, such as magnet sheets or PVC. Example: Industrial labels, thick stencil sheets, rigid signage.

Setting Up the Vinyl Cutter

Adjusting the Blade: Begin by properly setting up the knife (blade) of the vinyl cutter and adjust the knife tool screw as needed to ensure the blade protrudes just enough to cut through the vinyl without damaging the backing layer.

Loading the Vinyl Sheet: Manually insert the vinyl sheet into the machine, ensuring it is fed in straight. Flatten the material to remove any wrinkles or air bubbles that could affect cutting precision.

Aligning the Material & Stopper: Position the vinyl under the machine’s rollers and align it with the blue guides above. Adjust the stoppers (grit rollers) to securely hold the vinyl in place while allowing smooth movement.

Locking the Handle: Once aligned, lock the handle to secure the material in place. This step prevents any shifting during the cutting process, ensuring accuracy.

Initiating the Cutting Process: Start the machine, allowing it to perform an initial pass where the paper roll moves back and forth without cutting. This helps the machine estimate the total material size. After this check, the cutter will automatically pull the material back and begin the actual cutting process.

Safety Precautions: Keep hands and fingers away from the moving parts while the machine is running. Avoid making sudden adjustments or touching the material mid-process to prevent misalignment.

Vinyl Cutter Blade:



Position the vinyl under the machine’s rollers



Undertanding Interface.

Software

This vinyl cutter is complatible with the Graphtec Studio 2 Software. You can download Graphtec Studio 2 from the official Graphtec website. Link to download. It’s available for both Windows and Mac. It provides tools for vector-based design, text editing, and precise cutting control, making it an essential interface between your digital design and the vinyl cutter. Steps for Using Graphtec Studio with a Vinyl Cutter: Preparing the Vector File:

Create or obtain a DXF or SVG vector file for cutting. For my assignment, I used a Batman SVG available online.

Connecting to the Vinyl Cutter: Open Graphtec Studio software to establish a connection with the Graphtec vinyl cutter.

Opening the Design File: Go to the File menu and select Open to import the DXF or SVG file into the software.

Using Image Trace (Optional): If working with an image (JPEG, PNG), you can load it into Graphtec Studio. Use the Image Trace option to convert it into a vector for cutting.

Preview & Final Adjustments: Ensure the design is properly sized and positioned. Make any necessary modifications before sending it to the cutter.

Here we made an attempt of Using Image Trace: We loaded the Avenger logo by File>Open, Sacled it to the desired size and Vinyl printed it.

I enjoyed the printing process thus I went on printing a new sticker: I have added a detalied overview of my Graphtec Studio 2 sotware usage on my week 2 documentation. Check the Link here

Step 1: Install and Launch Graphtec Studio 2 from here

• Download the software from the official Graphtec website.
• Run the installer and follow on-screen instructions to complete the installation.
• Open Graphtec Studio 2 after installation.

step 2: Create or Import a Design.

• Import an Existing File:
  The linked I reffered to witch house
  
  Click “File” > “Open”. Here I opened an already existng vector to image trace.
  
  

• Step 3: Trace The image.

  Trace the image with the trace tool:

  

  Select the area type:

  

• Delete the actual image after forming the traced image:

  

  Click “Send” to transfer the design to your Graphtec cutter:

  

Final Outcome: Avenger logo



Final Outcome: Witch House

Kirigami

Inpiration form

1. Taking Inspiration from the above art work of Paul cocksedge I devised a concept and decide on the design – in this case, a parametric wave-like pattern. I used Adobe Illustrator and then Graphtec Studio 2, to create a vector file (DXF or SVG). Further I ensure the design consists of precise curved cuts that will lift off the base material in a controlled manner.

Design on Illustrator



Final Outcome: Witch House

2. Material Selection I Chose a thin sheet of cardstock for better flexibility. Ensured that the material is compatible with the Graphtec Vinyl Cutter.

3. Setting Up the Vinyl Cutter Loaded the material onto the Graphtec CE7000 vinyl cutter. Aligned it properly with the blue stopper guides to avoid misalignment. Locked the handle to keep the material steady during the cut.

4. Adjusting Cutter Settings Blade Depth: Adjusted the blade just enough to cut through the top layer but not completely detach the shapes to create a pop-up effect. Cutting Force: Moderated force to ensure clean cuts without tearing. Speed: A lower speed ensures more precision for intricate designs.

5. Cutting Process Sent the file to the cutter from Graphtec Studio 2. The cutter performs an initial pass to estimate material size before executing the actual cuts. The machine follows the vector paths, cutting the material accordingly.

6. Post-Cutting Handling Carefully lifted the curved sections without detaching them completely. Gently push the cut segments upwards to create the 3D wave effect seen in the image. Ensure the curves hold their shape without breaking.

7. Final Adjustments & Presentation Cleaned up any excess material or unwanted cuts. Folding the kirigami folds was an very inticate task here. I made a folding error in the first model and finally built the final model. Photographed the model with proper lighting to highlight its shadow effects and depth.

Kirigami Final Outcome:

Vinyl Sticker

Metal Engraving

Riidl Metal Engrave SOP