3. Computer Controlled Cutting

During Week 3 of computer-controlled cutting, I reviewed the safety guidelines for the laser cutters used at Moonlighter FabLab. The machines we use are manufactured by Full Spectrum, and I am already certified to operate the Full Spectrum laser cutter line.

Week 3. Computer-Controlled Cutting Group Project

Tasks

-Do your lab’s safety training.

-Characterize your lasercutter’s focus, power, speed, rate, kerf, joint clearance and types.

-Document your work to the group work page and reflect on your individual page what you learned.

Laser Cutter Certification and Safety Certifications

I earned my Laser Cutter Certifications for the Full Specrum P Series Lasers when I started working at Moonlighter FabLab.

Laser Cutter Characterization

Focus

The Laser Cutters at Moonlighter FabLab do not have the auto focus tool which means we are required to manually focus the focus head to the material using a laser cutter guide placed on the brass holder which would have housed the official focussing component. Focusing a laser is very important for the quality of the cut. A we well focused laser can produce sharper cuts with less unwanted burning.

Speed, Power and Current

Testing the speed and power is an important step in preparing a laser cut as it can save time and prevent the material from burning. I understand that a 1/8" sheet of bass wood can be cut through with 70 Speed, 70 Power, 100 Current and 1-2 passes.These values may changed depending on the calibration of the machine. An example of an unexpected difference would be when a lower power of 40-60 with 1 pass might cut through. This can meanthat the machine was recalibrated, the leveling was done incorrectly, or that the material was thinner or softer than expected.

We normally keep the current at 100 to ensure that our cuts have the best chance of going through the material. It is worth reducing the current for engraving operations.

Kerf

Understanding the kerf of the Moonlighter FabLab Laser Cutter was very helpful in this week's project. I knew that I would need to account for the kerf in som way but this was the first time I learned that there are actual values.

I designed a simple test for my cardboard using my usual method to getting a rough material thickness with a ruler. I made slots ranging from 3.4mm to 3.6mm to see which one would have the correct dimensions for my material and how the Kerf changes the fit.

I was able to get the material to fit in all 3 slots. the difference was very subtle differences. My conclusion is that in a difference form factor, the diffences in kerf would be more pronounced.

As I explored the training materials more deeply, I revisited the focusing protocol for the laser’s focus head, which involves using the focusing guide tool attached to the head itself. I also reviewed the key parameters of speed, power, and current.

Speed and power are the primary settings typically adjusted when programming cuts. I was already familiar with the concept that higher speeds reduce the amount of time the laser interacts with the material, while higher power increases the cutting force exerted by the laser.

Current, however, was a newer concept for me. I found it particularly interesting to learn that current influences the difference between producing dotted cuts versus continuous lines.

Vinyl Cutter

I opened the Sure Cuts Alot software on the vinyl cutter computer and imported the design files to the cut area.

I tried to layout the drawings in a way that it would minimize material wastage. This will take make practice to maximize my layout effectiveness. Onece that step was done, it was time to start cutting. This was a quick cut, apart from the time the vinyl sheet fell through the cutter when it was calibrating. Thankfully the cutter blade had no damages.

Using transfer paper, I was able to successfully apply my vinyl-cut logo design onto the container lid used for my project.

Laser Cutter Kerf Test

Parametric Push Fit Kit

Using a PCB layout similar to a keyboard, each tile will act as a key clicked with each player move. The cells will be numbered to follow a typical chess board I will need to study keyboard and key assemblies. The general idea is that the key assembly would allow the tile to click smoothly while the RGB LED shines through uninterrupted.