Computer-controlled cutting

This Week I worked on computer-controlled cutting

Assignment Brief:

  1. As a group assignment: Complete your lab's safety training.
  2. Test machine parameters: Runout, alignment, fixturing, speeds, feeds, materials, and toolpaths.
  3. Design a large (~meter-scale) object. Mill the designed object using the tested machine settings. Assemble the milled parts into a final product.

Computer-controlled cutting

A computer-controlled machine is a machine that operates using pre-programmed instructions from a computer rather than manual control. These machines follow precise digital commands to perform tasks like cutting, milling, engraving, 3D printing, or assembling.

CNC (Computer Numerical Control) Machines

A CNC machine is an automated manufacturing tool controlled by a computer using numerical commands. It eliminates the need for manual operation by following pre-programmed instructions, allowing for high precision, repeatability, and efficiency in shaping various materials like metal, wood, plastic, and composites.

Types of CNC Machines

How CNC Machines Work

Advantages of CNC Machines


Riidl Fablab CNC Machine: Numac Hitech CNC machine

The Numac Hitech CNC machine is a high-precision, large-format CNC router designed for cutting, engraving, and milling various materials. Given its 8' x 4' (2400 mm x 1200 mm) bed size, it is ideal for working with full-size sheets commonly used in fabrication and industrial design.

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Key Features

Group work

Safety instructions for using the CNC router:

Testing machine parameters: Runout, alignment, fixturing, speeds, feeds, materials, and toolpaths.

Recent Projects:

Fabricating 3D letters: TOSS

I, along with the help of my friends Sharvari Akerkar and Kanika Kadam. have recently built, designed and fabricating large 3D letters for TOSS, the annual sports event at Somaiya Vidyavihar University. Learn more about TOSS at the attatched link here. The event took place recently, and the goal was to create a bold and striking installation that serves as a visual centerpiece on the grounds of Somaiya Cricket Ground, Sion.

Find the complete documentation video at @abstract_s16.

Process: Design and Fabrication of 3D Letters, TOSS

1. Conceptualization & Design Development

The process began with designing the letters, ensuring they were visually impactful and aligned with the official TOSS event branding. The TOSS logo is as below

My learnings

1. Challenges in Working with Flexible Ply

Working with flexible plywood introduced unique challenges that needed to be addressed throughout the fabrication process.

Understanding Material Properties: Flexible plywood bends easily due to its thin veneers and specialized grain orientation. However, improper handling could lead to cracking or warping. It was essential to understand the material’s bending radius and apply gradual pressure during forming.

2. Design for Manufacturing (DFM) & Material Optimization

Designing with manufacturing constraints in mind was a crucial step to ensure efficiency and sustainability in production.

Optimizing Letter Sizes: One of the key considerations was optimizing the size of each letter to fit within a single standard plywood sheet measuring 8' x 4' (2400 mm x 1200 mm). This approach significantly reduced material wastage, minimized cost, and simplified the assembly process. Layout nesting techniques were used in Fusion 360 to arrange the letters efficiently on the sheet.


Parametric Book shelf

1. Conceptualization & Design Development
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My learnings

1. Slot Fit & Tolerance Adjustments

Precise slot dimensions are crucial. If the slots are too loose, the structure may wobble or collapse. If too tight, assembly becomes difficult and may require force, potentially damaging the material. While i build this structure I realized that my slot joinery was a loose fit, which made the structure stand on straight as well as slanted angles. The slanted angular structure was very firm, but it's base wasn't to the ground. On the other hand, If i placed the structure on with straigth lines, it was parellel to the base but the stability was a little low. Thought the model was functional, I realised that a kerf test was required before building the model.

3. Interlocking Strength & Stability

The interlocking nature of the slots provides structural integrity without requiring screws or adhesives. Slot positioning and orientation affect weight distribution. A crisscross or staggered slot pattern increases balance and load-bearing capacity.



My assignment

Layered art wall mount musical device.

A previous work on CNC had made me well acquainted with the processes and outcomes the machine could give. Thus, for this week I thought of building someething out of the box. I was suggested to go with something with ease of production, but that would limit my limit of reach. Further, I explored the intesity and exception of production of the CNC machine.

So I recalled that I aspired to build a wall mount interactive structure. This was my initial idea for final project of making an interactive wall mounted frame. Find the description about it in my final project documentation here.

I thought ways of interactivity, to which a musical emitting caught my mind. Using Human powered mechanisms, I thought of a design idea for a musical wall mount that serves as both a functional interactive unit and a decorative piece

Chat gpt prompt: Interactive wall mount

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Sketching the design Idea.

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1. Conceptualization & Design Development

One the sketch was ready, I Imported the image on Illustrator and traced each of the elements as different layers. gimp1

Import the image file on Illustrator: Open image> Copy> paste. gimp1
Make a new layer> Curvature tool> trace the bottom layer> gimp1
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Layer by layer segregation of each layer as would be on the model. gimp1 New Illustrator file> Layout of each file as new layer. gimp1 Further, I laser cut this file. As you see, one of the piece in the laser cut is burnt. this was due to the bed leveling. I set the bed level ande got that specific piece laser cut. To know more about laser cutting, Refer to my Week 3 documentation Computer Controller cutting

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Final Prototype gimp1

This is the prototype of my musical wall mount, created using layered cardboard to represent different structural elements. The blue pins indicate anchor points for strings, which will be stretched between them. Once attached, these strings can be plucked or strummed, producing sound, making the design not just a visual installation but also an interactive musical piece. This prototype helps visualize form, function, and material connections before developing the final version. The attatchment between each of the models will be with dowels.