Week 3 Computer Controlled Cutting

Week Objectives

1. Identify and explain processes involved in using the vinyl cutter

2. Demonstrate and describe parametric 2D modelling processes

3. Identify and explain processes involved in using the laser cutter

4. Develop, evaluate and construct a parametric construction kit

Vinyl Cutting

At the Charlotte Latin Fab Lab, we use Silhouette Studio to design and send files to the Cameo vinyl cutters.

I learned Silhouette Studio prior to Fab Academy so I did not need a tutorial to use the software.

I decided to use this image as a png file. I got it from here.

I imported the png file into visual studio, then scaled it down to my preferred size, then used Silhouette Studio's trace feature.

This is my traced design. I also added a rectangle around it.

I loaded a cut mat with grey vinyl onto the Silhouette Cameo vinyl cutter machine.

This is my cut after I weeded the excess vinyl with tweezers.

I cut rectangles with scissors then put those behind the empty spaces. A red rectangle behind the F1 logo cutout and a black rectangle behind the Formula 1 text.

Additionally, I put transfer tape over the design so I could transfer it to the Charlotte Latin Fab Lab sticker wall.

As you can see, my vinyl is on the sticker wall. This sticker wall is all the week 3 vinyl designs from the first 10 years of Charlotte Latin Fab Academy. As my class is the 10th year, I helped fill out the final row.

Design File

My design file can be downloaded by clicking vinyl_design.

Lab Safety

Laser cutters are a very powerful but also dangerous machine in a Fab Lab. The danger comes from fire. Laser cutters often cut bio based carbon materials like carboard or wood, which are very flamable. When cutting, small fires are common. These fires must be watched however they are not a problem if they are small and go out. If the fire does not go out, that is a problem.

If a fire doesn't go out, there are two important things to do first. Call over someone who works at the lab (for me, teachers or fab academy instructors). These people will fight the fire, not me. Second, it is important to keep the lid closed. The lasers have natural exhaust systems sucking all of the air out. These exhaust systems help lasers fight fires by drowning them out. If you open the lid, oxygen can come rushing into the laser cutter fueling the fire.

When a laser is running, you must not leave it. Fires can happen unexpectedly during the cutting process and can damage the laser cutters, and even burn down the whole building.

Another way fires can start is if the laser gets stuck in one position but the laser remains on. This releases a massive amount of energy into one spot. This causes way more damage than a material catching on fire. This is how the most dangerous laser cutter fires start.

Make sure the emergency stop is accessible in case anything goes wrong.

Parametric Construction Kit

This week, I tried something new in Autodesk Fusion. I used parameters in my design. With parameters, I would be able to input a value for a variable like kerf, then my design would automatically update to fit the new dimensions for kerf.

Parameters are very useful because I wouldn't need to go back into my design and change every value for everything affected by kerf. I can even put in equations using things other variables. For instance I could make one dimension equal to kerf + dimension3.

Parameters still take a decent amount of time to set up. I found them to be useful in larger models where changing dimensions would be very time consuming, but less useful in smaller models where dimensions can be changed quickly.

For my Parametric Construction Kit, I wanted to design a sleek looking storage box with a adjustable divider.

I designed this construction kit in fusion. After I had sketched out all the dimensions I started working on the parameters.

These are all the parameters I added in my design. Because I had never done anything with parameters in fusion before, I looked at Fab Academy graduate Andrew Puky's Computer Controlled Cutting Page to learn how to do parameters.

Additionally, Max Negrin, another fab academy student, helped me with which types of parameters I should add.

This is the box I designed in Fusion. I used slot and tab press fit joints to joing my pieces because the joint type is effective and small. I made most of my parameters around the slots and tabs so I could change things like kerf and still retain the desired fitment.

This is the the box after cutting. Because I downloaded the sketch as a dxf, all of my lines were vectors which made the job setup on the epilog software easy. I used the cardboard cutting settings in the material settings and then I sent the job to the laser.

Because the divider was actually in a different sketch, my dxf file did not contain it. I had to export the sketch as a dxf containing the divider and then cut again.

As you can see, the divider has no slots or tabs. This is because it is supposed to fit tightly inside while still being able to be moved around or removed entirely.

This is my box fully assembled. All of my joints held together tightly because my accomodation for kerf and tolerance. This box felt very sturdy. The design looks very modern and the divider is very easy to move and is very practical for sorting materials.

Design File

My file can be viewed and download by clicking here.

Link to Group Project

Click here to access my group project

Reflection

I found this week to still not be to bad, but harder than the previous two weeks. This week was the first time I had done a group project. The logistics part was new and documenting on the same repository was new. I got used this progress and I feel more comforterable planning and documenting on future group projects.