This week focuses on laser cutting and vinyl cutting techniques for precise material processing and digital fabrication.
Assignment Requirements
Individual Assignments:
Design, lasercut, and document a parametric construction kit, accounting for the lasercutter kerf
Cut something on the vinyl cutter
Project Overview
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.
I also created a fully parametric version of the torus design in Fusion 360. The key advantage of parametric design is that you can change a single value — like material thickness — and the entire design updates automatically. Here's how I set it up:
Step 1: Adding User Parameters
In Fusion 360, I went to Modify → Change Parameters (or press S and search "parameters"). This opens the Parameters dialog where you can create custom variables. I clicked the + button under "User Parameters" and added:
cardboard_thickness = 3.53 mm — the measured thickness of my cardboard material
kerf = 0.254 mm (0.01 inch) — the laser kerf from our group testing
slot_width = cardboard_thickness + kerf — this is a formula, so it auto-calculates to 3.784 mm
The power of this approach: if I switch to a different material (say 3mm acrylic), I just change cardboard_thickness to 3.0 mm and every slot in the design updates instantly.
Step 2: Assigning Parameters to Sketch Dimensions
When sketching the crescent pieces, instead of typing a fixed number for the slot width, I typed the parameter name slot_width directly into the dimension input box. Fusion 360 recognizes it as a variable and links that dimension to the parameter. Any dimension in any sketch can reference these parameters — so every slot across both crescent piece types uses the same slot_width value.
I also constrained the overall crescent dimensions (outer radius, inner radius, arc angles) with parameters so the entire design is adjustable from the Parameters dialog without touching any sketches.
Step 3: Verifying the Parametric Constraints
To verify everything was linked correctly, I temporarily changed cardboard_thickness to a different value and confirmed that all slot widths updated throughout the design. Then I changed it back to 3.53 mm for the final cut.
Fusion 360 Parameters dialog — user parameters for cardboard thickness, kerf, and slot width with formula-based values
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.
Laser cutting the crescent pieces for the sliceform torus construction kit
Final Assembled Torus
The completed sliceform torus — all crescent pieces interlocked and assembled
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.
Multi-color Ford Bronco vinyl cut with chromatic stripes
Silhouette Studio cut settings for the Bronco background
.jpg)
