Overview
Computer-controlled cutting translates vector geometry into real parts. Although the machines are different, both workflows depend on the same fundamentals: correct scale, compatible file formats, and settings matched to the material.
- Laser cutting: rigid materials (wood), kerf and tolerance affect fit and accuracy
- Vinyl cutting: adhesive vinyl, clean paths and careful weeding decide the final quality
Laser Cutting — Makeblock Laserbox
Software setup
The Laserbox workflow starts with installing the official software. I downloaded it from: https://support.xtool.com/article/182.
Workflow note: canvas size vs. material size
One limitation of the Laserbox software is that the design canvas represents the full machine workspace, not the exact size/position of the sheet placed inside the machine. When importing an SVG, scale can drift if the file setup is not strict.
For this assignment I used an A4 sheet, so I created an A4 rectangle (210 × 297 mm) in Illustrator and kept my cut geometry inside that frame. This made it easier to verify scale and keep the design within the real material boundary after importing into Laserbox.
Machine specifications
| Parameter | Value |
|---|---|
| Model | Makeblock Laserbox |
| Laser Type | CO₂ Laser |
| Laser Power | 40 W |
| Working Area | 500 mm × 300 mm |
| Software | Laserbox software |
| Supported File Formats | SVG, DXF, PNG, JPG |
| Typical Materials | Wood, paper, cardboard, leather, acrylic |
Tolerance test
Before cutting the final design, I ran a tolerance test to evaluate cutting precision and estimate kerf. The result confirmed that the cuts were clean and consistent for this material batch.
Laser cutting settings (record)
Fab Academy reviewers often look for a clear record of settings. The table below documents the parameters used (values may vary depending on material condition).
| Item | Value |
|---|---|
| Material | Plywood |
| Thickness | 3 mm |
| Operation | Cut |
| Power | 80% |
| Speed | 10 mm/s |
| Passes | 1 |
| Air Assist | Enabled |
| Focus | Auto Focus |
Press-fit Construction
Concept — Tessellation
For the press-fit task, I explored tessellation as a strategy to create repeating modules. Tessellation is a geometric method where a single tile can repeat and fill a plane without gaps or overlaps, which makes it a good starting point for modular construction.
I created the tessellation on tiled.art, which helps visualize how a single shape behaves when repeated. Based on that logic, I designed a bird (dove) tile that can connect with identical pieces.
Vector design in Illustrator
I redrew the tile as clean vector paths in Adobe Illustrator and arranged multiple copies inside an A4 boundary to maximize material usage and keep scale consistent for laser cutting.
Press-fit slot design
To enable assembly without glue, I added press-fit slots to the bird geometry. The material was 3 mm plywood. Since laser cutting is accurate and kerf removes a small amount of material, I designed the slot width as 2.6 mm to achieve a tight friction fit.
Laser cutting the sheet
Removing and checking the fit
After removing the parts, I tested the slot tolerance by assembling two pieces first. The 2.6 mm slot width produced a secure connection while still allowing disassembly.
Assembly experiments
This press-fit experiment shows how a 2D tessellation tile can become a modular construction system. The repeating bird shape supports multiple assembly directions, producing both flat patterns and small 3D forms.
Vinyl Cutting — Silhouette Cameo 5a
For vinyl cutting, I designed a lung-shaped sticker with branching structures and circular details. This geometry tests both cutting precision and how difficult the design is to weed.
Design
File format issue
When importing the design into Silhouette Studio, I encountered a file format limitation. Some vector formats are not supported in the basic edition. To solve this, I exported a compatible format (DXF) before importing.
Importing the design
Machine setup
- Select machine model: Cameo 5a
- Set cutting mat size
- Select material type
Preparing material
Cutting process
Weeding
Final result
Reflection
- Laser cutting requires understanding kerf and tolerance.
- Design scale must match the real material size (the A4 frame helped a lot).
- Tessellation is a strong strategy for modular design, and press-fit slots can turn a 2D tile into a 3D construction system.
- Vinyl cutting requires clean vector paths and correct import formats.
- Complex designs increase the difficulty of the weeding process.