Computer-Controlled Cutting

From our group work/research, we found the kerf on the laser cutter to be 0.01 inch. This measurement is critical for designing parts that fit together properly, as the laser removes material equal to the kerf width when cutting.

My Group Work Contributions

For the group assignment, I wrote the Terms and Definitions section, covering the key laser cutting vocabulary: Focus/Focal Point, Power, Speed, Kerf, and Joint Clearance/Types. Each term includes a detailed explanation of what it means and why it matters for laser cutting. You can see my contributions on the group assignment page.

How I Compensated for Kerf

To account for the 0.01 inch kerf in my parametric construction kit, I adjusted all slot widths by adding 0.01 inch to ensure proper fit. For example, if the cardboard thickness was 3.53mm, I designed the slots to be 3.53mm + 0.01 inch to compensate for the material removed during cutting.

Why Kerf Matters

• The laser beam has a physical width that removes material
• Without compensation, parts will be too loose or won't fit
• Parametric design allows easy adjustment for different materials
• Testing is essential to verify the kerf measurement

For my personal laser cut parametric construction kit, I was inspired by a sliceform torus design. This elegant geometric form is created by interlocking crescent-shaped pieces that assemble into a three-dimensional torus shape.

Design Inspiration

I found inspiration from this YouTube video that demonstrates the sliceform torus concept and provides a great explanation on how to assemble the design:

Design Process

CorelDRAW Design

I decided to start modeling this in CorelDRAW. I created 2 crescent moon shapes and added 6 grooves - one on the outside and the other on the inside of the crescent arch. Both grooves are aligned parallel, meaning if you were to continue drawing the line following from a crescent with the groove on the outside to the inside, it would be in the same spot.

The groove width is 3.53 mm, which matches the cardboard thickness I used for the project.

CorelDRAW Files:

• Download Part 1.cdr
• Download Part 2.cdr

Fusion 360 Parametric Design

I also set parameters in Fusion 360 to create a fully parametric version of the design. I constrained the sketch with set parameters, one of them being the width of the cardboard slits in the design. This parametric approach means I can easily adjust the design for different material thicknesses by simply changing the parameter values.

Fusion 360 File:

• Download Fusion Torrus Design.stl

Laser Cutting Process

The laser cutting process went smoothly after accounting for the 0.01 inch kerf. The pieces fit together perfectly, demonstrating the importance of accurate kerf compensation in parametric design.

Final Assembled Torus

Laser Cutting Tips

• Always do a test cut with your material first
• Verify kerf measurements before cutting final pieces
• Ensure material is flat and secured to the bed
• Check focus height for clean cuts
• Monitor the cutting process for any issues

For the vinyl cutting project, I decided to create a Ford Bronco design. I wanted to incorporate the classic chromatic side stripes, but I knew it would be difficult to achieve the same color fade as the real vehicle. Instead, I split the stripes into three solid colors to better match what the vinyl cutter could produce.

Design Concept

I chose a gray/silver color to add contrast and used a white background to help the design stand out. The colors I used were:

• Black - Base layer and Bronco silhouette
• Silver/Gray - Contrast and detail
• Red - Chromatic stripe section
• Yellow - Chromatic stripe section
• Orange - Chromatic stripe section
• White - Background layer for contrast

Layering Process

For most of the colors, I cut the exact same Bronco shape, removed the sections I didn't need, and layered the correct colored pieces onto the black base. The white layer was done differently. I added it after finishing the other layers because I believe it improves the overall contrast, especially since the stickers will be placed on the lab window.

Cutting & Assembly

I cut the design using a Cricut machine to ensure clean, precise edges. The multi-layer approach required careful alignment to ensure each color piece fit perfectly on the base layer.

For the background of the Bronco, I used Silhouette Studio and cut it at school to gain more experience with other software and devices. The basics are the same as my Cricut at home, so I was able to do it pretty quickly.

Design Files

Download the Bronco design files:

Key Skills Developed

• Understanding kerf compensation in laser cutting design
• Creating parametric designs that can be easily adjusted
• Working with CorelDRAW for 2D cutting paths
• Using Fusion 360 for parametric constraint-based design
• Vinyl cutting techniques and multi-color application
• Importance of material testing and characterization
• Assembly techniques for interlocking construction kits

Challenges Overcome

• Accurately measuring and compensating for kerf
• Designing grooves that align perfectly for assembly
• Creating parametric constraints in Fusion 360
• Aligning multiple vinyl layers precisely

Future Applications

The skills learned this week will be valuable for:

• Creating custom enclosures and housings
• Designing interlocking parts for assemblies
• Making signage and labels with vinyl
• Prototyping flat-pack designs
• Building construction kits and puzzles