Week 3: Embedded Programming
This week I learned how to use the Thunder Laser Cutting-NOVA 24 to make a phone stand.
Week 3 Group Work
Week3 Group Assignment - Our group assignment webpage
Team collaboration: test the laser cutter tolerances
1.Design a tolerance test gauge in a 2D software
2. Export the file and send it to the laser cutter for cutting, then measure how the machine performs at different dimensions
3. Identify the minimum gap that the laser cutter can cut accurately
4. Adjust laser cutting parameters to achieve the best cutting results (power, speed, etc.)Document the process from designing the test gauge to obtaining the optimal results
Reflection of what I learned
This week, I learned how to use the Thunder Laser Cutting-NOVA 51 to make a phone stand.
While using the laser cutter, I learned the safety rules and how to use the laser cutter safely. Here are a few key takeaways.
Design a phone stand using LaserMaker software based on the tolerance tested in the groupwork.
I tested the tolerance of the laser cutting machine with my team members using different sizes of holes and bars, both horizontally and vertically. I performed the laser cutting twice due to the machine’s tolerance issues, and as a result, the plywood could not be inserted into the socket holes at the first time. The second time， the width was adjusted from 2.9mm to 3.2mm， so that the plywood could fit into the socket hole properly.
- We should always wear the laser safety goggles at all times when operating the laser cutter.
- There is a camera on the laser cutter. After the laser cutting is completed, we can check the cutting results by watching the camera. Do not move the board until the laser cutting is completed.
- After the laser cutting is completed, we should wait for the board to cool down for a few minutes before removing it from the laser cutter.
- A higher speed is not always better; we should choose the appropriate speed for the material. When cutting a corner, if the speed is too fast it can cause excessive charring that weakens the wood fibres. When setting the parameters, the angular power should be tested at about 60% of the total power.
About the safty training:
Safety Training
- Inspect the machine – Check for any damage, loose cables, or debris inside.
- Check ventilation – Ensure exhaust/fume extraction is working to remove hazardous fumes.
- Use approved materials only – Never cut PVC, vinyl, ABS, polycarbonate, or reflective metals (e.g., bare copper, brass) – they release toxic gas or damage the laser. Use wood, acrylic, paper, cardboard, or manufacturer‑approved materials.
- Focus correctly – Set the correct focal distance for the material thickness.
- Close the lid – Always operate with the protective cover fully closed.
- Wear laser safety goggles at all times when operating the laser cutter.
- Fire extinguisher location — a CO₂ extinguisher is mounted next to the machine; never use a water extinguisher near electrical equipment.
- Know the emergency stop — the big red button on the machine immediately halts the laser and the motion system.
Useful links
- Lasermaker
- Find the perfect Fit Tolerance for Laser Cutting
- 拼插设计Lasermaker.dxf — source file (DXF)
- Bunny iPhone stand.icpx — source file (icpx)
Individual Assignment
This week, I designed a phone stand and made a press-fit constrciton kit by using the laser cutter.
1.Laser Cutting Workflow Part 1
Designing a press-fit constrction kit using LaserMaker software.
Open LaserMaker software and create a new project.Cleck circle button to draw a circle.Then choose a heart shape from the shape library and draw a heart shape. Use the alignment tool to align the centers of the two shapes.
Select the circle to get the center point of the circle.Remember the X and Y coordinates of the center point.Then select the rectangle and use the circular array tool to make more rectangles.
Remember to change the coordinates of the circular array to the center point of the circle, fill in the step angle 90 degrees and copy number 4, don't tick the Relative Centerize checkbox.Then the rectangles will be surrounded on the circle.
The center point of the circle is (228.75,117.01).So the center point of the circular array is (228.75,117.01).
Select each rectangle and use the Difference Set Tool on the left side of tool bar to trim the outside part of the rectangle.
Select the whole shape and use the Grid Array Tool on the left side of tool bar to make the shape into a grid. Set up the horizontal count to 4, horizontal interval to 10mmand vertical interval to 40mm. Then you will get multiple shapes that looks the same. Download the .dxf format file and send it to the laser cutter.
Set the speed to 30mm/s and Min Power to 70% max power to 90% then click Start Job button to start the laser cutting.
If an emergency arises suddenly, press the red emergency stop button.
2.Laser Cutting Workflow Part 2
1.Search from the webset to see how to use the laser cutter to make a phone stand, and the idea about how to design the phone stand. 2.Designing the phone stand in LaserMaker software, and export the .icpx file.
3.Send the .icpx file to the laser cutter, adjust the parameters and material of the laser cutting, and wait for the laser cutting to complete.
4.After lasering, the press-fit constrciton is not designed well, so it's hard to assemble them together, I think the reason is becasuse the tolorance of the width of the socket and the thickness of the wooden board is not accurately matched, so I am using the vernier caliper to measure the width of the socket and the thickness of the wooden board and record the data.Then I adjust the parameters of the laser cutting to make the press-fit constrciton more accurate.
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