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Week 03 - Computer-Controlled Cutting

We got an introduction to Fusion from Dani and designed this piece to test tolerance and fit between the joints.

We then got a tour of the laser cutters at Fab Lab Barcelona.

Laser lab at Fab Lab Barcelona

Laser cutters at Fab Lab Barcelona

We have the following laser cutters in the lab:

  • Rayjet 500 (the one we tested with)
  • 60W CO2 laser cutter
  • Bed size: 500 × 300 mm

  • Max material thickness: ~10 mm

  • Rayjet 400

  • 40W CO2 laser cutter
  • Bed size: 400 × 300 mm

  • Max material thickness: ~8 mm

  • Epilog Legend 36EXT

  • 60W CO2 laser cutter
  • Bed size: 914 × 610 mm

  • Max material thickness: ~10 mm

  • Trotec Speedy 100

  • 30W CO2 laser cutter
  • Bed size: 610 × 305 mm
  • Max material thickness: ~6 mm

Note: Material thickness values are approximate since they depend on the material type, focus distance, machine setup, and power/speed settings.

We then did a small test on the Rayjet 500 to understand how the machine worked.

Laser cutter test 1

Laser cutter test 2

Laser cutter test 3

Laser cutter test 4

Laser cutter test 5

Each machine has its own focus tool. We focused the machine by keeping the laser height at 0.

Focusing the laser cutter

Fusion tolerance design

Safety and Process Considerations

  • Always close the top lid of the machine before starting the cut.
  • Ensure proper ventilation in the workspace to avoid inhaling fumes from cutting materials. Turn on the valves, switches, ventilator, and exhaust fan while working with the machine.
  • Use appropriate materials for laser cutting. Avoid cutting materials that can release toxic fumes, such as PVC or certain types of foam.
  • Always perform the inside cuts first to prevent the material from shifting during the cutting process.
  • Always do a test cut before starting the final cut to ensure the settings are correct. There are test swatches available in the lab, and it is useful to test both material settings and design tolerances.
  • Be cautious when cutting reflective materials since the laser system uses mirrors to direct the beam. Reflective surfaces can redirect the laser unexpectedly and potentially cause damage or injury. It is recommended to cover one side with temporary masking material to absorb excess laser energy.

We cut the parts in acrylic to test the tolerance fit that Dani showed us how to design in Fusion.

We used the settings from the test swatch. I used the lab computer connected to the machine to start the cut.

Laser cutting acrylic parts

Tolerance comb test

We also took the test required to join the booking system and learned how to use it.