Week 3. Computer-Controlled Cutting¶
Group Assignment¶
This week, the work began in a group format, during which we first became familiar with the structure of the laser cutting machine and its safety rules. During the practical phase, an inspection and adjustment of the laser system’s optical path was carried out. First, the position of the laser beam was checked using a transparent acrylic plate, since this material allows the impact point of the beam to be clearly visible without producing excessive smoke.
Acrylic was chosen instead of paper because a paper test could have burned the surface and generated smoke that might reach the mirrors, potentially damaging or contaminating the machine. Based on the obtained marks, the beam position was evaluated at different points.
Afterward, the transmitting mirrors were adjusted.
Using the alignment screws mounted on the mirror modules, the beam direction was carefully corrected to ensure that it passed through the center of the optical path and accurately reached the working head. The adjustment process continued until the test impact points coincided with the intended centers. As a result, it was confirmed that the optical path of the laser system was properly aligned and that the machine was ready for safe and precise operation.
Engraving and cutting¶
We created test samples to identify the optimal engraving and cutting settings for two materials: cardboard and plywood.
The cutting and engraving parameters are different for each material and also depend on the specific machine settings.
After the engraving and cutting process, we proceeded to a kerf calibration test to determine the optimal joint dimensions.
Laser Cut Kerf Test Drawing¶
Before assembling the construction kit, a test was conducted to determine the amount of material removed by the laser during cutting (kerf). Since the material thickness is 4 mm, it was necessary to determine the joint size that would ensure a tight and accurate fit.
For this purpose, a parametric test model was created in FreeCAD, containing slots ranging from 3.00 mm to 2.50 mm with a 0.05 mm step. This makes it possible to precisely identify the optimal joint dimension.
After that, the file was exported as a DXF file.
Since our laser machine operates with LightBurn software, the design file was exported in a compatible format and prepared for cutting.
The DXF file was opened in LightBurn. Text was added to the drawing, and the design was duplicated. The cutting areas were then selected and their parameters were assigned. After that, the engraving regions were defined and their corresponding settings were configured. Finally, the cutting process was executed.
After cutting, the joints were tested sequentially by fitting them into each other. The best fit was achieved at 2.75 mm, which provided the optimal balance between tightness and ease of assembly.
Based on the fitting test results, it was determined that the optimal joint dimension was 2.75 mm, which provided the best balance between tightness and ease of assembly. Comparing this value with the nominal design range led to the conclusion that the effective kerf of our laser cutting machine is approximately 0.25 mm. This value was therefore taken into account for adjusting the final design parameters to ensure accurate and reliable joints.
Vinyl Cutting¶
About our Vinyl Cutter¶
In our laboratory, we use the Roland VersaStudio GS2-24, a vinyl cutting machine designed for precise cutting of vinyl, heat-transfer films, and other thin materials. The machine features a compact design, stable performance, and high cutting accuracy, making it suitable for graphic design, labeling, and decorative applications.
| Parameter | Description |
|---|---|
| Device model | Roland VersaStudio GS2-24 |
| Cutting Width | 22.9 in (584 mm) |
| Material Width | 1.97 – 27.5 in (50 – 700 mm) |
| Maximum Cutting Speed | 0.39 – 33.4 in/s (10 – 850 mm/s) |
| Cutting Force | 30 – 500 gf |
| Repetition Accuracy | ≤ 0.1 mm |
| Interface | USB 2.0, Ethernet |
| Power Supply | AC adapter 100–240 V → 24 V DC 2.7 A |
| Dimensions | 860 × 319 × 235 mm |
Here are the components of a vinyl cutter and how it is built.
And this is the blade that cuts our material.
Testing, Setting knife force¶
When I turned on the machine, it performed a home position setup, and the display immediately showed the function to choose the type of sheet. There are three options available:
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Roll
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Piece
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Edge
Since I am going to do a test, I decided to use the material in roll form. To do this, I place the roll between the clamping rollers and the main shaft, clamp the rollers onto the material, and then select roll* in the sheet selection menu.
After selecting Roll, the machine does not measure the full length, but only detects the width of the material using the sensors located at the front and back of the cutting area. The length is considered unlimited, as the material is fed continuously from the roll.
For example, the machine detected the material width as W: 584 mm. Even though the real width of the vinyl is 600 mm, the machine keeps a safe margin of about 3–3.5 cm on both sides to avoid cutting outside the usable area or damaging the blade.
To achieve accurate cutting results, two main parameters must be set:
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Force
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Speed
These parameters are highly dependent on the type and condition of the vinyl. Room temperature and storage conditions play a significant role, because vinyl can deform depending on temperature. As a result, the same vinyl may not be cut accurately with the same force and speed settings if it has been stored in different environmental conditions.
Therefore, it is always necessary to run test cuts before starting the final job and adjust the force and speed accordingly.
Time to set the force for the knife. To do this, press the “Force” button, choose the force, and hold the “Test” button.
I tried cutting my material at several depths to determine the correct cutting depth. I started from 50 gf up to 120 gf. From 80 gf, the cut was already ideal, but I continued testing. At 120 gf, the material was cut all the way through.
After completing these steps, the file is imported into Cut Studio, the software used to operate our machine.
Then, I set the dimensions of my design.
I move the machine head to the area of the material where I want the cutting to start, then press and hold the Origin button so the machine recognizes that point as the starting position.
In the software, when I select Cutting, a window opens where I choose Move to Origin so the machine cuts from the position I specified.
And then I start the cutting process.
After cutting, I apply transfer tape onto the material so I can lift and separate the parts I need.
And then I decide where to place it on my computer.
