3. Computer Aided design

Goal of this week

group assignment:
      • do your lab's safety training
      • characterize your lasercutter's focus, power, speed, rate,
         kerf, joint clearance and types
   individual assignment:
      • cut something on the vinylcutter
      • design, lasercut, and document a parametric construction kit,
         accounting for the lasercutter kerf
      • extra credit: design it to be assembled in multiple ways
      • extra credit: include elements that aren't flat
      • extra credit: engrave as well as cut

My working plan:

• Review lecture video and read tutorial, understand what should I learn for this week and how could I learn. (2 hours)
• Group assignment online (4 hours)
• Learn to use my own laser cutter, characterize the cutter’s power, speed, kerf, joint (1 hour)
• Design, lasercut, and document a parametric construction kit (3 hours)
• Cut something on the vinylcutter (not finish due to lab close)
• Finish documentation

Group assignment

This week my teammates gathered in Shanghai formshop lab, but I still need to work so I can only join them online. After our group do all the test in Shanghai, I test my local laser cutter and learn how to use it with Nancy.

Formshop Fab Lab 2026 group member: Yaro, James, Winnie, Zequan Lin and me

Safety training

We are using a **Thunder Laser** DC CO2 glass tube laser system for this week’s cutting and engraving tasks. Safety training is essential before operation, as the laser can easily cause fires and generate smoke.

On the top of the machine, there is a large red emergency stop button, which should be pressed immediately in case of any danger.

Both the cooling system and the air extractor must be turned on during the entire working period.

Lasercutter sample making

Before cutting, we need to run a test sample to determine the appropriate settings (speed and power). This time, we selected 2mm plywood, 2.5mm acrylic, 0.7mm fabric, and 4mm cardboard for the test.

Operation process:

1. Power check: Ensure the main switch, laser switch, cooling system, and air extractor are all turned on.
2. File check: Draw the cutting paths in the software, confirm the speed and power settings, then send the file to the laser cutter. Adjust the cutting sequence and parameters layer by layer as needed.
3. Material check: Measure the material thickness using the calliper.
4. Material Fixing: Secure and flatten the material firmly using strong magnets in cutting area.
5. Laser Focusing: Use a gauge to set a 6mm gap between the material surface and the laser head.
6. Set Origin: Move the laser head to the desired starting position, then press the “Origin” button to set it.
7. Frame Check: Press the “Frame” button to preview the cutting area and verify the pattern size.
8. Close Lid: Securely close the machine’s protective lid.
9. Begin Cutting: Press the “Start” button to start the cutting process.

Material Testing Matrix Generator

The optimal power and speed settings follow a key principle: use the maximum speed achievable with the minimum power required. This approach balances processing efficiency with the long-term preservation of the machine.

We can pre-set the parameter and save as a default setting.

This is a control panel that help us visually check.

To adjust the focus, first loosen the screw with one hand while supporting the laser head with the other to prevent it from dropping. Then, insert a 6mm gauge between the material and the head to set the gap. Finally, tighten the screw to secure the head and press the “Origin” button to confirm the position.

Zero the calliper and measure the thickness of material.

We tested cutting parameters for plywood, acrylic, corrugated paper, and fabric. The optimal settings for each material are listed below :

Note: Due to variances in material batches, storage, and equipment, the following parameters are reference values and may require adjustment.

• 2mm Plywood: Speed = 70 mm/s, Power = 80 %.
• 0.7mm Fabric: Speed = 94 mm/s, Power = 19 %.
• 4mm Corrugated Paper (3 layers): Speed = 48 mm/s, Power = 49 %.

• 2.5mm Acrylic Board: Speed = 18 mm/s, Power = 84 %.

  

  

  

Warning: Fire Risk with Corrugated Paper

This material is prone to ignition. Never leave the laser unattended during cutting. Keep a fire blanket or extinguisher accessible. If fire occurs, stop the machine immediately and extinguish the flames.

Caution: Thin Fabric Settings

The laser can easily burn through thin fabric. Always start with very low power or high speed settings, and conduct a test cut to fine-tune parameters.

Bend test

It’s surprising how much plywood can bend! The flexibility really depends on the pattern you use.

Joint test

For 2mm Plywood, the joint width is best between 1.65mm～1.70mm

Kerf test

Kerf: 100.6mm-100mm=0.6mm, Kerf=0.6/11=0.055mm

Material Template

The Template include: Text size, Engraving test, bend test, through test.

---

Cut testing result

Photo from Yaro

Testing Sample Documents

When importing an .SVG file into LaserMaker, the dimensions may occasionally be inaccurate. For improved reliability, you may also import the design using the .DXF file format.

Note: Measure the dimensions in LaserMaker before cutting.

Working with my local laser cutter

In my lab we have a  **Thunder Laser** DC CO2 glass tube laser cutter, the same type with shanghai form shop lab, but our cutter is in the corridor so each time we need a long tube to pipe gas out and after we finish cutting works, we need to pull the pipe back to the room to keep the room temperature.

In our lab we have 2.5mm plywood, so I need to retest the speed, power, and joint test

I found 80 mm/s speed , 30% power and 2.40-2.45mm joint is the best me. But after I try more cutting, I increase 2% power to 32% and choose 2.40mm joint in my future work.

Individual assignment

I was a stem teacher in kindergarten so I played interlocking building pieces a lot with my kids and this time I decided to make three different shape (square, circle, rectangle ) of pieces and make a tribal mask for my wife. since I do not have a lot of time stay with her after I join fab academy:) We agreed that when she puts on the mask, I will stop my FabLab study and go to be with her.

I use fusion 360 to do the parametric design, first I create parameters of the dimensions, I set the length of the square, rectangle and the dimension of the circle as 40mm, the size for joint slot as 6mm*2.4mm, the dimension of the inner circle as 8mm.

   I start with a sketch and draw a square and 4 joint slot, set the length, width of the square and joint slot as the parameter I defined

Then I try to put all the slot to the center of each edge, I defined the distance between the left corner of the square and the joint slot as (squarewidth-slotwidth)/2 and do the same thing on the right. After that the slot stick to uncenter of the square.

for circle and triangle I did it in the same way. the distance between the center of the bottom line of the slot and the circle is dimension/2-slotlength. and the distance between the two slots is dimension-slotlength*2. After the setting you can change the parameter and the slot will stay at its position.

Then I use circular pattern, pick 4 edges of the slot. set center point as the circle center and quantity 8.

for the rectangle I just repeat set parameter and circular pattern.

after I have all the models, I export sketch as dxf and open them in Lasermake 2.0,

I use grid array to copy 25 pieces from 1

I set the power and speed and send it to the server. I download the the file to the laser cutter labtop from the server and send it to the cutter. Then autofocus, set position, choose file, check edge inside the wood pad and start cutting!

---

Last update: February 11, 2026