Reflection
This week was super cool! Our online team met up in person for the first time in Shanghai to get hands-on with laser cutting.
What we learned:
Safety first! We got trained on how to use the machine. Then came testing-finding the best speed and power for materials like wood, acrylic, and cardboard. The golden rule: use the lowest power that still gets the job done, and speed it up as much as possible. Fast, clean, and easy on the machine.
Problems we ran into:
- Thin fabric burns through-turn the power down.
- Cardboard catches fire easily-never walk away.
- Files sometimes import at the wrong size-always double-check.
Laser cutting makes creating things fast, fun, and full of surprises.
Schedule
| Time | Wed | Thu | Fri | Sat | Sun | Mon | Tue |
|---|---|---|---|---|---|---|---|
| 08:00-10:00 | |||||||
| 10:00-12:00 | |||||||
| 12:00-14:00 | Document | ||||||
| 14:00-17:00 | Document | Document | Document | ||||
| 17:00-22:00 | |||||||
| 22:00-00:00 | Neil's class | ||||||
| 00:00-01:00 | class |
Group Assignment
Formshop Fab Lab 2026 group member: Yaro, James, Winnie, Yanfeng and me
Safety training
Lab Safety Rules
- Authorization Required. Complete all safety & equipment training before using any tools.
- Plan Your Work. Identify risks (fire, fumes, moving parts) for your materials and process before starting.
- Wear Proper PPE. Always wear basic protection (safety glasses, closed-toe shoes). Use extra gear (laser goggles, gloves) for specific hazards.
- Use Approved Materials Only. Never use banned materials (e.g., PVC for laser cutting).
- Never Leave Unattended. Stay at the machine/experiment during high-risk or active operations.
- Maintain a Safe Environment. Ensure ventilation is ON, area is clean, and fire extinguishers/blankets are accessible. Keep exits clear.
- Know Emergency Procedures. Locate emergency stops, exits, and first-aid kits. Report all hazards and incidents immediately.
- Clean Up and Log Out. Power down equipment, dispose of waste properly, return materials, and restore the workspace to a clean, safe state.
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:
- Power check: Ensure the main switch, laser switch, cooling system, and air extractor are all turned on.
- 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.
- Material check: Measure the material thickness using the calliper.
- Material Fixing: Secure and flatten the material firmly using strong magnets in cutting area.
- Laser Focusing: Use a gauge to set a 6mm gap between the material surface and the laser head.
- Set Origin: Move the laser head to the desired starting position, then press the "Origin" button to set it.
- Frame Check: Press the "Frame" button to preview the cutting area and verify the pattern size.
- Close Lid: Securely close the machine's protective lid.
- 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=0.6mm
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.
Lasermaker files (with setting)
SVG files
Individual Assignment
It was fascinating to see plywood become flexible through strategic patterning. This revelation sparked an idea: could this feature be used to create an interlocking construction kit?
To explore how to structure such a kit, I began by reading Arturo's foundational article on the topic. Interlocking, Ribbing and Folding: Explorations in Parametric Constructions.
I try the bend structure for it.
Parameter Construction Kit setting in Fusion 360
As a parameter kit, I set up the thickness as a reference size (joint gap), in case to change the other board.
The initial design had a height of 20mm and a length of 50mm. However, I found these dimensions too small for practical assembly. In the next iteration, I doubled the length to 100mm and introduced a joint gap in the middle.
To account for the laser kerf (based on prior test results), I applied a 0.3mm outward offset to the cutting outline firstly.
The joint fits perfectly at a 90-degree angle with a 1.7 mm gap. However, in my design, the connections involve angled joints, which require a larger gap for smooth assembly. After testing, I found that a 1.95 mm gap works best.
Export as .DXF file and import to Laser Maker. Use Array Tool to grid it, bingo, sent to machine to cut it.
Through experimenting with up-and-down joints for the first prototype, a bouncing pad emerged. I was delighted to discover its engaging interactivity - similar to pressing a keyboard key. Upon impact, it rebounds like a spring.
To expand the joining methods, I experimented with side-cut connections for multi-directional assembly. I haven't yet found another suitable shape to make, so I've put the initial construction idea on hold for now.
Drawing inspiration from previous student work, I realized I shouldn't limit the design to a single shape. Creating varied forms can give the overall structure more life and functionality.
Based on test results, the optimal joint gap for 2mm plywood is 1.7mm. I used a parametric approach: (Material Thickness - 0.3mm). By doubling this adjusted dimension in the design, two kits can be securely layered and merged.
I also create a Grasshopper version parameter kit, which can adjust the width, Length and the thickness.
Note: Bending Direction is Critical. The bend line must be perpendicular to the wood grain or primary cutting direction. If misaligned, the material becomes fragile and is likely to crack.
Following the kit design, I created these bouncing toys. Using the laser cutter was a fantastic experience - it truly makes physical creation more interesting and dramatically faster.
Documents
Vinyl Cutting
Using Adobe Illustrator, I designed our lab's logo for the "Reprography and Printing Innovation Platform." The logo visually combines the letters "R" and "P" in an overlapping layout to represent "Reprography." I tend to use a vinyl cutter to produce this design as a physical sticker.
Preparing for Vinyl Cutting in Adobe Illustrator:
- Expand Text: Convert all text to outlined shapes using Type > Create Outlines.
- Inspect Paths: Carefully examine the artwork. Any paths that intersect or cross through a shape may cause cutting errors.
- Merge Shapes: To resolve this, select all overlapping elements and use the Pathfinder panel (Window > Pathfinder) to apply the Unite function. This merges them into a single, continuous shape.
- Final Check: Ensure the final design consists of clean, unified paths before sending it to the vinyl cutter.
To to continued, It is hard to access the vinyl cutter during holiday, I will update after holiday.