Vinyl Cutting

For the first part of this week, I worked with vinyl cutting. I wanted to make something fun, so I decided to create a Honda-themed vinyl decal. I used the Cricut machine to cut the design.

Before cutting, I had to learn how to prepare vector graphics correctly so the machine could follow the lines. I adjusted sizing, placement, and cut settings before sending the file to the cutter.

Once the vinyl was cut, I removed the extra material by hand using a weeding tool. This part took patience because small pieces can easily tear or pull up if you move too fast.

After the design was cleaned up, I used transfer tape to move the decal onto another surface. This helped me understand how vinyl graphics are layered and transferred cleanly.

Laser Cutting

The second part of this assignment focused on laser cutting using the Epilog Fusion Edge laser cutter. I worked on learning how vector cutting works and how power, speed, and frequency settings affect cuts.

One thing I learned quickly is that different materials react very differently to laser settings. Too much power burns the material, while too little power does not cut all the way through.

Castle Project

For my laser project, I made a small castle-style structure using press-fit construction. The goal was to create parts that could slot together without glue.

I designed the parts so the tabs and slots would interlock tightly. This required testing the kerf of the laser cutter so the slots were not too loose or too tight.

After cutting the pieces, I assembled the structure by hand. Some slots fit perfectly, while others needed small adjustments. This taught me how important tolerances are in computer-controlled cutting.

Kerf Testing

One of the most important parts of this week was understanding kerf. The laser removes a small amount of material while cutting, and that changes how tightly parts fit together.

I tested different slot sizes to see what fit best for the material I was using. Once I found the correct size, the parts locked together much better.

What I Learned

• How vector cutting works with vinyl cutters and lasers
• How to prepare files for cutting machines
• How to weed and transfer vinyl decals
• How laser speed and power settings affect materials
• How kerf changes part fitment
• How press-fit construction works
• Why tolerances matter in fabrication

Problems I Ran Into

One challenge was dialing in the laser settings correctly. Some cuts burned too much while others did not fully cut through the material.

I also had to experiment with slot sizing because some parts were either too loose or too tight. Once I adjusted for kerf, the assembly worked much better.

Final Thoughts

This week helped me understand the difference between designing something digitally and actually fabricating it with machines. Even small design changes can completely affect how parts fit together in real life.

I also learned that computer-controlled cutting is not just pressing a button. Material setup, machine settings, tolerances, and file preparation all matter if you want a clean result.