3. Computer Controlled Cutting

This week's assignment is to design a parametric kit and then cut it using the laser cutter. We will also be using a vinyl cutter.

For more information about materials and uses of the laser cutter as well as more parameters that are used, go to our GROUP PAGE .

I'm going to explain a little bit about what I did this week:

1. My kit

Equations in SolidWorks

This is the most important tool for parameterizing parts. The steps to use it are as follows:

Open SolidWorks and create a new part, then go to the Tools menu.
In the Tools menu, look for the Equations option located near the bottom.

URL with HTTPS — **Figure 01. Components of a Laser Cutting Head**

The Equations, Global Variables, and Dimensions manager will open; here, you must declare your Global Variables by first giving them a name and then assigning a value.

When using the Smart Dimension tool, you can call these global variables or perform operations by typing ="variable_name" in the dimension box. To use operations, follow this format: ="variable_name1" + "variable_name2".

Parts of my kit

Circular piece

To make it easier to make changes to my circle, I set a variable to modify the diameter, the thickness of the material I used, the kerf, the length of the cross in the middle, the length of the edge cuts, and the number of cuts in my figure, so that by simply modifying the values here, my entire design is updated.

Export

To export the necessary files for the laser cutter software, follow these steps:

Save the parts previously created.
Open SolidWorks and create a new Drawing.

Select the Model View tool.

Add the desired part using the Browse option in the menu.

Drag and drop the part onto the drawing sheet.
Double-click on the part to change the scale of the drawing as needed.

Go to Save As and select the DXF format.

2. Laser Cutter

Laser Cutting Head Components

Laser Generator:This is the light source that creates the beam. It is usually a CO2 tube that generates a high-power infrared beam.
Beam Bender (Mirror):Its function is to redirect the laser path (which exits the generator horizontally) downward toward the material.
Focusing Lens:One of the most critical parts. It concentrates the wide light beam into an extremely small and powerful point (called a "spot") on the material's surface.
Laser Focusing Head:The structure that protects the lens and mirrors, moving along the X and Y axes to execute the design.
Nozzle:The tip where the laser exits. In addition to directing the beam, pressurized air (air assist) usually passes through here to blow away burnt material, prevent fires, and protect the lens from debris.
Focal Length:The exact distance between the lens and the point where the laser is thinnest and most powerful. For this week's task, correctly adjusting the focus is vital for achieving a clean cut.
Workpiece:The material you are going to cut or engrave, such as wood, acrylic, or cardboard.

For the calibration is important to maintain a distance of 5mm between the nozzle and the material.

Machine Controls

Machine

The machine I used for this task was the CFL-CMA1390T.

Chiller

The first thing we must check is the chiller, as it circulates distilled water through the tube to maintain a constant and safe temperature.

Automatic Voltage Regulator

The second step is to turn on the automatic voltage regulator of the laser.

Machine On

Afterward, we turn on the machine using the button located on the right side.

We release the emergency stop.

Laser Head

This machine has a head for two lasers.

Laser Power Knobs

On the top part of the machine, we will find these knobs to control the laser power.

Laser Control Panel

The laser control panel is activated after inserting and turning the key.

We must give it a moment to power up, and then we can start moving the laser with the arrow keys; to set an origin, we must press the Origin button.

USB Memory

Once we have the file in .ou format, which is the one we get from SmartCarve, we insert the USB memory into the bottom part of the machine and press the File button.

We move through the screen with the arrows and press +Udisk.

Then, Read Udisk.

Copying to RAM

Once we have the file we want selected with Enter, we click the option Copy to RAM.

Starting the Cut

We return to the file menu by pressing the Esc button.

Now that we have the file in the laser, click Enter, and then to see if our file fits on the material, we can press the Frame button.

To begin cutting, we must increase the laser power with the knobs, press the white button, and then press Start-Pause.

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3. Smart Carve

To operate the laser cutter, you must use the SmartCarve software. Please note that this program will only open if the specialized USB security dongle (key) is inserted; otherwise, the software will not function.

Import your design

Once you have saved your file in .DXF format:

Open SmartCarve.
Go to the top menu and select File.
Choose Import File and select your design.
Choose Import File and select your design.

Setting Parameters by Color

On the main interface, the parameter configuration menu is located on the right side. You can assign different colors to different parts of your design to apply specific settings (e.g., separating engraving from cutting).

Example: Engraving Settings (Green Layer)

Max Power: 12
Min Power: 7
Work Speed: 170

Setting Parameters by Color

Example: Cutting Settings (Red/Default Layer)

Max Power: 60
Min Power: 50
Work Speed: 40

Rotation

On the left side of the main page, you will find the rotation menu. To rotate a piece, locate the circle icon, enter your desired angle, and click Apply.

Drawing

The Draw menu allows you to add basic geometric shapes or text directly within the software without needing to re-import a file.

Export

To export the file in .ou format, which is the one the laser uses, you will find this menu in the lower right part of the screen; click on the File Save option, select the location you want, and that's it—you now have the file for the laser.

Testing Parameters

To determine the appropriate parameters, I performed several tests by adjusting the maximum power, minimum power, and speed.

First Square: I tested the parameters 65, 60, 30.
Second Square: I tested 45, 40, 30.
Circle: I tested 60, 50, 60.
Pentagon: I tested 60, 50, 40.

Result

In the end, the parameters I chose were 45, 40, 30, and these were the results for my pieces.

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4. Vinyl Cutter

I selected images of a cat and a shark for this task. To prepare them, I processed the files in Inkscape to create vector paths, which is a necessary step for the vinyl cutter to follow the outlines accurately. You can see how I vectorized mi images in the Week 2 assignment.