Week 16. Wildcard Week¶
The main goal of this week’s assignment was to explore and experiment with a fabrication process that we had not previously used during earlier assignments, as well as to carefully document the entire production workflow.
For this purpose, Gevorg and I visited a local workshop in our city where several types of metal fabrication machines were available. The process that interested us the most was Laser Cutting of Metal. During the visit, the operators introduced us to the structure of the laser cutting machine, its working principles, and the main safety procedures.
We had the opportunity to observe how the laser beam processes metal sheets with high precision and creates the required parts.
Machine Specifications¶
| Laser Type | Fiber Laser |
|---|---|
| Power | 6 kW (6000W) |
| Model | 4015–6000W CNC Fiber Laser Cutting Machine |
| Laser Source | MAX Photonics MFSC-6000 |
| Software | CNC Control Software |
| Supported File Formats | DXF, DWG, AI, and other vector-based CAD files |
| Working Area | 4000 × 1500 mm |
The machine used in the workshop was a high-power industrial laser system designed for precise cutting of metal sheets up to 2 cm thick. It had a separate control panel containing the power, control, and safety buttons.
We were also introduced to the Emergency Stop button, which is used to immediately stop the machine in emergency situations. In addition, the panel included Power, Active, and Alarm indicators showing the current state of the machine.
The panel also contained several important control buttons and indicators. The Drive button was used to activate the motion system responsible for moving the laser head. The Laser button activated the laser source and allowed the cutting process to begin. The red indicator on the left showed that the machine was powered on, while the illuminated green buttons indicated that the corresponding systems were active.
Control Panel¶
The machine also had a separate handheld control panel that allowed the operator to manually control the laser head and different machine functions.
The panel included directional buttons, laser activation controls, return functions, pause/start controls, and several other operational buttons.
This controller was especially useful during the calibration phase, when it was necessary to manually move the laser head, define the starting point, or check the cutting process. It allowed more accurate control over the workflow and made it easier to quickly react to necessary adjustments.
Nozzles and Gas Usage¶
After learning about the machine controls, we also studied the laser nozzles, which play an important role in ensuring cutting precision and quality.
Different nozzle diameters were used depending on the thickness of the metal and the type of cut. In the workshop, we were told that 1.2 mm, 1.4 mm, 1.5 mm, and other nozzle sizes were commonly used. Smaller nozzles provide more precise and detailed cuts, while larger nozzles are better suited for thicker materials because they remove molten metal more efficiently from the cutting area.
Since we were cutting 1.2 mm thick metal, we used a 1.2 mm nozzle. Choosing the correct nozzle was very important because it directly affected the cutting precision, edge quality, and overall result. With this nozzle, we achieved clean and even cuts without unwanted deformation or material damage.
When cutting metal with a thickness of 3 mm or more, oxygen is commonly used to ensure cleaner cuts and prevent slag from remaining on the backside of the material. Oxygen increases the pressure, making it easier and more efficient for the laser beam to pass through the metal.
When the gas pressure is sufficiently high, the cut becomes smoother and cleaner. If the pressure is too low, the nozzle may become damaged, the cutting quality decreases, and slag or molten material may remain on the backside of the metal.
For metals thinner than 3 mm, compressed air or nitrogen is generally used because high pressure is not required. Thin metal is easier for the laser to penetrate, making it possible to achieve clean and precise cuts even under lower pressure conditions.
Using nitrogen or compressed air also results in cleaner edges with less oxidation. Additionally, the chance of damaging the nozzle is lower during thin metal cutting.
Safety Rules¶
During the machine demonstration, we were also introduced to the main safety rules that had to be followed while working with the laser cutter. Since the machine operates at high temperatures and contains high-speed moving systems, following safety procedures was essential both for proper workflow organization and for avoiding potential hazards.
- Wear protective safety glasses while staying in the working area.
- Do not stand near the moving rails, since they move at high speed.
- Do not touch moving machine parts during operation.
- Wait until the machine completely finishes its process before approaching the work area.
- Maintain a safe distance from the machine throughout the cutting process.
Design Part¶
During this week, I was thinking about how I could apply the fabrication process explored in Wildcard Week to my final project. I decided to separate some elements from the upper part of my final project design and cut them from metal at a smaller scale.
After completing my final project, I plan to transform these elements into a separate product, either as a small desk lamp or a wall-mounted decorative light object. This idea would allow me to reuse the developed design in a new format and further explore the combination of metal and lighting in small-scale products.
I took the AI-generated image of my final project and gave it back to ChatGPT with the following prompt to generate the wall lamp concept I wanted.
Transform the upper circular sculptural part into a compact modern wall lamp, removing the lower/base section completely. Keep the abstract intertwined ring design, make it realistic for wall mounting, around 15–20 cm in size, with soft warm ambient LED lighting and a minimal contemporary aesthetic․
Since I had already created the 2D version of my final project sketch during Week 2, I first checked which file formats were supported by the workshop’s laser cutting machine. I found out that it accepted both SVG and DXF files.
I exported my design as a DXF file because it is widely used in CNC and laser cutting workflows. Then I transferred the file to the machine using a USB flash drive and imported it into the control software with the help of the operator.
The first step was machine calibration. After that, the Z-axis was adjusted so that the laser head would be positioned at the correct working distance from the metal surface.
After importing the DXF file into the software, it was necessary to verify that the part was correctly positioned on the metal sheet. For this, we used the “Рамка” (Frame) tool, which allowed the machine to outline the area where the cutting process would take place. This helped us confirm the placement in advance and avoid wasting material.
Once everything was properly configured, we started the cutting process. However, during the first attempt, we realized that the software was not displaying the cutting sequence correctly, and the laser cut the outer contour first. As a result, the part separated from the metal sheet and fell before the internal sections had been completed.
To solve the problem, we used a special tool in the software that creates bridges (tabs). These tabs intentionally leave small uncut sections that keep the part attached to the sheet until the entire cutting process is finished.
We added several tabs in appropriate locations and started the cutting process again.
During the second attempt, the part remained fixed to the metal sheet throughout the process, and after the cutting was completed, it could be easily separated from the sheet.
As a result, we obtained a clean and precise metal part without deformation or the issue of the part falling during cutting.
Conclusion¶
During this week, I was able to learn about the operation of an industrial fiber laser cutting machine and observe how metal laser processing is performed in real production conditions.
Although the available time was limited and we could not fully explore all the machine’s capabilities, the experience was still very useful and interesting.
Throughout the assignment, I was able to apply my own design, prepare the DXF file, and produce a real metal-cut component. In addition, this assignment helped me think about how I can apply this fabrication process in my final project and transform my design into a small metal lighting object.