Week 17 – Wildcard week
This week is about trying or deriving new computer-added process and exploring new machines.
The objective is to explore a new computer-added process with the new machine that is not covered in the previous weeks and make something with that process or machine. I decided to use embroidery machine to design and produce embroidery on a cotton cloth that I can use in my final project.
AI prompt: "Hey, I am in my week 17 Wildcard week, this week is about design and produce something with a digital process (incorporating computer-aided design and manufacturing) - I have decided to use Embroidery Machine - Brother se2000, first design a 2D embroidery design and then use machine to CNC Embroidery on a Cotton fabric and use it for the male waistcoat of my final project. in the embroidery I will stitch Neopixels. The Embroidery that I designed is from my Mom's embroidery reference. Can you please give me a animated fun image of me doing week 17 of my fab academy? "
Assignment Overview
- Design and produce something with a digital process (incorporating computer-aided design and manufacturing) not covered in another assignment, documenting the requirements that your assignment meets, and including everything necessary to reproduce it.
| Day | Activity | Status |
|---|---|---|
| Thursday | Class - Wildcard week possible options to explore | Completed |
| Introduction to Embroidery Machine Brother SE2000 🛠 adn Documentation | Completed | |
| Friday | 2D Embroidery Design 📐 | Completed |
| Saturday | Final Project - Updated the Schedule 📝 | In progress |
| Design, Produced and Tested "Embroidery Pixel" 🛠 | Completed | |
| Sunday | Documentation 📝 | Completed |
| Embroidery Material / Cloth from Local Shops | In progress | |
| Monday | Fabric Cutting on the ZUND machine 🛠 | Pending |
| Embroidery work using Brother se2000 🛠 | Pending | |
| Tuesday | Regional Review 👨🏫💬 | Completed |
| Embroidery work using Brother se2000 🛠 | Pending | |
| Wednesday | Stitching using Brother se2000 🛠 | Pending |
| Documentation 📝 | In progress |
Digital Embroidery
As the Embroidery work is involved in my final project, I chose to explore the digital embroidery process for my this weeks assignment.
Digital Fabrication Process/Workflow : Hand Sketching (PNG) --> Fusion (DXF) --> 2D Design (SVG) --> Inkscape --> INK/Stitch (PES) --> BROTHER SE2000
2D Sketching
Different regions of India has different Embroidery Styles. I took reference of my mom's embroidery which is done with Rabari Style of Embroidery.
I decided to make two embroidery designs, for one I took reference from my mom's embroidery work. She made one piece of Kutchi embroidery style / Rabari embroidery style work.
Fusion and 2D Design SVG
I used Fusion to generate SVG file. First I imported PNG file in to fusion then used Spline tool to drew outlines and finally used mirror tool to multiply the patent.
From above file I generated / exported a DXF file and used Concertio.co to convert DXF into SVG. You can download DXF file from here Embroidery_Fusion. Now opened the SVG file into Inkscape. I used Join Selected Nodes to join individual splines. First, Click Node Tool --> Select the two splines --> Select the joining nodes --> Join selected nodes. I need to do this only for splines that are touching the mirror lines.
I filled the color using HEX Code values of different colors. Boolean Operation : Select inner circle --> Object --> Raise to top --> Select both circles --> Path --> Difference.
INK/Stitch
Download Ink/Stitch Extension for Inkscape. The Ink/Stitch automatically finds the Inkscape extension folder and installs itself.
BROTHER SE2000
What Went Wrong
What I Learned
Garment drafting / Pattern cutting
As I decided to make the waistcoat within the lab, first thing is to cut the patterns for my size using Zünd cutting machines and then do the embroidery work and Stitching using BROTHER SE2000.
Digital Fabrication Process : 2D Garment Draft in Fusion (DXF) --> Cut Editor : CAM Files --> Cut Queue (Job Server) --> Cut Center (Job / CAM Executor) --> Zund Machine
2D Garment Draft
Cut Editor
Cut Center
Zund Machine
What Went Wrong
What I Learned
Embroidery Pixel Module
I decided to make Embroidery pixel module in the lab and then use it in the embroidery work. To do this, my instructor suggested to use Carvera PCB Machine because I can multiply the modules in the gerber to PNG layout and then mass-produce it with less wastage.
Digital Fabrication Process : KiCAD PCB Design --> Gerber to PNG (Layout for 40 Modules)--> Mods CE (Generate G-Code) --> Carvera Controller --> PCB Milling --> Soldering --> Testing on Jig --> Done!
KiCad PCB Design
First, I made the schematic design with WS2812B and used 0.1 uF capacitor across the positive and negative act as local energy storage.
Gerber to PNG (Layout for 40 Modules)
I used Layout option in Gerber2PNG to generate Layout for milling 40 Modules. As si was going to use Carvera Machine, I selected Generate for Carvera and then in Layout Setup, I entered 5 rows and 8 columns and downloaded the PNG. This steps need to be done for both TraceLayer and DrillLayer.
Mods CE (Generate G-COde)
Now, we need to open these PNG files of TraceLayer and DrillLayer into ModsCE to generate the G-code/Tool path for Carvera Machine.
When we start mods and load Carvera the default values are different . But after opening mods and clicking " load file " from the left side bar I added below file which will setup the defaults values that fits our machine, so that's e don't have to change it every time. CarveraMODSSV4.4.json
We can verify the Tool path using online NC Viewer or also in CARVERA CONTROLLER Software.
Carvera Controller
Carvera Controller Tool that we can install and use to connect with Carvera Machine wirelessly via wifi. The tool can be downloaded for here --> Carvera & Carvera Air Controller.
Below is its home screen and follow below Steps for setup.
- Step 1: Connect to wifi by clicking on "NA" button
- Step 2: Click "None" button and Select "Prob" : the machine will begin do Automatic calibration.
- Step 3: Click "Side Aero" button, a new screen will slide from the right, set the job origin using x+/x- and y+/y- buttons.
- Step 3: Click "Side Aero" button, a new screen will slide from the right, set the job origin using x+/x- and y+/y- buttons.
- Step 4: Click "Set Origin" Enter X-offset:0 and Y-offset:0, select "current pos"
- Step 5: Click "Config and Run" select Auto leveling enter x-points and y-points.
- Step 6: Click "Open" in the left bottom and open the G-code file.
- Step 7: Click "Upload & Select" and then "Run"
PCB Module Milling
PCB Module Soldering
