Computer-Controlled Cutting

This week at FabLab was all about lasers, design, and hands-on learning. We learned how to use the laser cutter and vinyl cutter while experimenting with different settings and materials. Honestly, it was quite exciting (and slightly intimidating at first), but by the end of the week, it felt like we had mastered it. Well...almost!

Safety Training & Machine Characterization

Safety First!

Safety training is a must before working with any powerful machines like laser cutters or vinyl cutters. Our instructor walked us through essential safety measures to avoid accidents and ensure a smooth workflow.

Here’s what we covered:

Always wear Personal Protective Equipment (PPE), like safety glasses, especially while working with the laser cutter.
Emergency stop button: We were shown how to use it in case of equipment malfunction.
Fire safety procedures: Understanding how to deal with potential hazards when working with lasers.

Vinyl Cutter Characterization

The first machine we explored was the Graphtec Vinyl Cutter, and we learned how to set up and fine-tune its settings for different designs.

What we learned:

Blade Adjustment: The blade must be properly adjusted to cut the vinyl without slicing the backing sheet.
Roller Positioning: The rollers should be aligned with the media to avoid misalignment during cutting.
Software Setup: We used design software to convert images into cuttable vector designs.

First Demonstration: Avengers Logo

Our instructor demonstrated how to cut an Avengers logo on red vinyl.

Initial Settings: Force and speed were adjusted to get clean cuts.
Observation: Precise weeding (removing excess vinyl) is critical for detailed designs.

Key Insights:

Proper force adjustment is crucial—too much force cuts through the backing, and too little leaves parts uncut.
Detailed designs require more care during weeding to avoid tearing small elements.

Laser Cutter Characterization

Next, we moved on to the CO2 Laser Cutter in our lab. This was an exciting experience because we got to see how the laser tube works and how the beam travels to the focal point.

Photo Observations

Here are some key moments from our training:

Adjusting the vinyl cutter blade and force settings.
Learning about the CO2 laser tube and how the laser beam is directed through mirrors to the cutting head.
Characterizing the vinyl cutter by cutting simple and detailed designs like the Avengers logo and observing how adjustments impact the output.

CO2 Laser Tube

The CO2 laser tube generates the laser beam, which is reflected through a series of 45-degree mirrors before it reaches the cutting head.
Focal Point: The final mirror directs the beam through the focusing lens at the cutting tip. Adjusting this focus is essential for accurate cuts.

What we learned about laser cutting:

Power and Speed Settings: These control how deep and fast the cut happens. Finding the right combination prevents burning or incomplete cuts. Kerf Measurement: We tested the kerf by cutting small pieces and measuring the material loss. Accounting for kerf ensures a snug fit for interlocking parts.
Focus: Precision is key. We tested and adjusted the focus to get clean cuts.
Power, Speed, and Rate: Tweaking these parameters was like tuning a race car for the perfect performance.
Kerf Measurement: Kerf—the material lost during cutting—is a small but critical detail. We measured and accounted for it in our designs to ensure a perfect fit.
Joint Clearance: Finding the sweet spot between a snug fit and "impossible to assemble" was the challenge here.
Material Types: From acrylic to plywood, we tested various materials to see how the laser performed on each one.

Joint Clearance:For assemblies, we experimented with different clearances to find the perfect balance between tight and loose fits.

Devanshi's page

Mihir's page

Designing a Parametric Construction Kit

For this project, I designed a parametric construction kit inspired by Y-shaped structures commonly found in nature and architecture. The idea was to create a modular set of interlocking pieces that could form various configurations. The design focused on flexibility, allowing the pieces to be assembled in multiple ways to create interesting structures.

Design Inspiration

The core design was inspired by Y-shaped structures that are frequently seen around us, such as:

Tree branches
Antlers
River tributaries
Lightning branches

Design Process

Sketching and Conceptualization

I began by drawing several ideas for Y-shaped interlocking pieces. The goal was to make a design that could be easily replicated and modified using parametric settings.

Digital Modeling in Fusion 360

Creating a Sketch

I started by drawing the basic Y-shaped structure using the sketch tool.
Added dimensions to define the key lengths and slot sizes. Defining User Parameters
Opened Modify → Change Parameters in Fusion 360.
Added User Parameters: Slot Length (AB) = 5 mm, Slot Width (ST) = 2.8 mm (Considering the 1 mm laser kerf).

Applying Constraints

Used collinear and perpendicular constraints to keep the shape geometrically stable.
ssigned the slot width and length to parametric values, making adjustments easy.

Finalizing and Testing Adjustments

Modified the material thickness in User Parameters to see if the slots automatically adjusted—this ensured the design was fully parametric.
Once confirmed, I exported the DXF file for laser cutting.
Material Used: 3 mm corrugated cardboard
Kerf Calculation: Our machine has a kerf of 1 mm, so I adjusted the slot width to 2.8 mm to ensure a snug fit.
Slot Dimensions: Length: 5 mm, Width: 2.8 mm

Setting Laser Cutter Parameters

I prepared the file in RDWorks and set the laser cutting parameters for corrugated cardboard:

Speed: 15 mm/s
Min Power: 60%
Max Power: 65%

These settings ensured clean cuts without burning the cardboard.

Laser Cutting and Assembly I loaded the design onto the CO2 laser cutter and cut several Y-shaped pieces. After cutting, I assembled the pieces into various configurations. The process was fun and allowed for a lot of creative exploration.

Final Output

I created two main structures:

Giraffe-like Structure – Resembling a giraffe with long, graceful "legs" and a curved body.
Tank with Missile Launcher – The second structure looked like a man sitting in a tank, aiming a missile launcher—definitely a more playful creation!

Reflections & Key Takeaways

Parametric Design Rocks! Setting up parametric dimensions in Fusion 360 saved me a lot of time when adjusting for the kerf and slot width.
Kerf Matters: Even a small kerf can significantly affect the fit of interlocking pieces. Proper measurement is essential for achieving a snug fit.
Experimentation Leads to Fun Structures: The flexible design allowed for endless combinations, resulting in some unexpected and cool-looking shapes.

This project was a perfect mix of technical learning and creativity. I’m excited to refine the design further and try it on different materials!

Vinyl Cutting

For this task, I dived into vinyl cutting to create custom decals. The idea was to start simple and then gradually move to a more complex design. My goal was to get comfortable with the vinyl cutter's settings and understand how force, speed, and blade adjustment can impact the final output. Here's how it went:

Step-by-Step Process:

1. Design Creation

Using Graphtec Studio 2 for Vinyl Cutting

For my vinyl cutting project, I used Graphtec Studio 2, the software provided by Graphtec for designing and preparing files for cutting.

Key Features of Graphtec Studio 2:

Import & Trace PNGs: Allows importing raster images (like PNGs) and converting them into vector outlines for cutting.
Node Editing: Enables fine-tuning of the vector paths for precise cutting.
Cutting Condition Settings: Lets users control force, speed, and tool settings for different materials.
Alignment & Positioning: Helps in arranging multiple designs efficiently on the vinyl sheet to minimize material waste.

Design Preparation in Graphtec Studio 2

Importing Designs: I imported PNG images of a skull and a dragon into Graphtec Studio 2.
Tracing the Image: I used the trace function to convert the PNG into a cuttable vector path.
Adjusting Cut Settings: For the simple skull, default settings worked fine, but for the dragon, I had to increase the force to ensure proper detail cutting.
Finalizing & Cutting: After setting the correct force and speed, I sent the design to the Graphtec vinyl cutter, which precisely cut the outlines. Using Graphtec Studio 2 helped streamline the process, making it easy to prepare detailed designs for cutting with minimal manual adjustments.

2.Machine Setup & Initial Attempt

I used gold vinyl for the dragon decal. Initial settings:

Force: 10
Speed: 5 cm/s

However, during the first cut, I noticed the vinyl wasn’t cut properly. The intricate details were incomplete, and the vinyl peeled inconsistently. Why? The force was too low for the complexity of the design.

Failed Attempt: Vinyl Cutting the Dragon

During my first attempt at cutting the intricate dragon design on gold vinyl, I encountered an issue—the cutting force was too low. As a result:

The finer details, such as the scales and curved edges, were not cut properly.
Peeling (weeding) the excess vinyl became difficult since the cuts didn’t go all the way through.
Some parts tore or stretched, affecting the final output.

Lesson Learned: Adjusting the cutting force is crucial, especially for complex designs. After this, I increased the force and successfully cut the dragon with much cleaner details!

3.Adjusting the Settings

I increased the cutting force to 16, ensuring the blade could cut deeper without damaging the backing. This adjustment made all the difference. The second attempt was much better, and the details of the dragon design came out perfectly.

4.Cutting Process & Weeding

Once the design was cut, I moved on to weeding—removing the excess vinyl around the design. This part required patience, especially with the tiny details of the dragon’s scales and curves.

5.Application

The final step was applying the decal to a black acrylic board. I carefully transferred the decal using transfer tape to avoid air bubbles and misalignment.

6.Observations & Challenges:

Initial Failure: The first cut failed due to insufficient force. It taught me how crucial it is to match the force with the design complexity. Weeding Complexity: More intricate designs take longer to weed, but the final result is worth the extra effort. Proper Transfer: Using transfer tape made applying the decal much easier, ensuring the design stayed intact.

Final Output:

Here’s how the vinyl decals turned out:

Simple Skull Decal

Easy to cut and weed Perfect for understanding the basics of the machine Intricate Dragon Decal (Second Attempt)

Complex and detailed, with sharp curves and edges Applied on black acrylic for a striking contrast

Project files

Parametrc Module (.dxf)

Skull (.png)

Dragon (.png)