MISSION BRIEFING
This week is all about subtractive manufacturing. The goal is to characterize the machines (Group Work) and then use them to create a Press-Fit Construction Kit (Laser) and a custom sticker/circuit (Vinyl).
COMPUTER-CONTROLLED CUTTING
The Art of Destruction: Lasers & Blades
01. GROUP ASSIGNMENT
Before cutting anything serious, the team gathered to test the machine's limits. We characterized the Power, Speed, and most importantly, the Kerf.
MISSION LOG: JOINT OPERATION
We tested the laser cutter focus, power, speed, rate, and kerf. The data collected was crucial for my individual press-fit kit.
We tested the laser cutter focus, power, speed, rate, and kerf. The data collected was crucial for my individual press-fit kit.
DEBRIEF!
MISSION LOG: LASER PROTOCOL & TROUBLESHOOTING
Operating the laser is not just pushing a button. Here is the strict protocol I learned, including a critical error I made with the Z-Axis focus.
Operating the laser is not just pushing a button. Here is the strict protocol I learned, including a critical error I made with the Z-Axis focus.
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1. VECTOR PREP:
Export the design as a DXF file (R14 version usually works best). Ensure all lines are joined and remove any duplicate lines to avoid double-cutting. -
2. SYSTEM START:
Turn on the laser, the chiller (water cooling), and the air extractor. Safety is paramount: never run the laser without ventilation. -
3. ORIGIN (X, Y):
Move the laser head using the arrows on the control panel to set the starting point, optimizing material usage to reduce waste. -
⚠️ CRITICAL FAILURE: THE Z-AXIS
The Problem: My first attempt failed. The cut was thick and blurry, and it didn't go all the way through the MDF. I realized I had ignored the focal length.
The Fix (Calibration): The nozzle MUST be exactly 5mm away from the material surface.
I used the metal spacer tool (calibrated gauge) to adjust the bed height manually. I moved the laser up until there was a space of exactly 5mm between the nozzle tip and the material surface. This 5mm gap is the "sweet spot" where the laser beam is most concentrated and powerful. -
4. PARAMETERS & FIRE:
Send the file from the PC. Double-check Speed (20) and Power (60). Hit "Start" and never leave the machine unattended while it's working.
01. THE VINYL FRONTIER
For this mission, I decided to customize my laptop. I designed a decal using Inkscape and prepared the file for the vynil cutter machine.
SETUP!
MISSION LOG: DESIGN PHASE
I prepared the vector file and configured the machine parameters.
I prepared the vector file and configured the machine parameters.
Fig 1. Vector Setup
Fig 2. Loading the Vinyl
MACRO!
MISSION LOG: CLOSE-UP
A closer look at the weeding process and the transfer tape application before the final deployment.
A closer look at the weeding process and the transfer tape application before the final deployment.
Fig 3. Weeding Detail
Fig 4. Transfer Tape Ready
MISSION LOG: AUTOMATED CUT
The machine executes the cut. The blade depth was calibrated to cut the vinyl but leave the backing paper intact. I used 60 speed and force was 360g for a clean cut.
The machine executes the cut. The blade depth was calibrated to cut the vinyl but leave the backing paper intact. I used 60 speed and force was 360g for a clean cut.
Video 1. The cutting process
DEPLOY!
MISSION LOG: EXECUTION
The complete manual workflow: Weeding the excess material, applying the Transfer Tape, and finally sticking it to the laptop surface.
The complete manual workflow: Weeding the excess material, applying the Transfer Tape, and finally sticking it to the laptop surface.
Video 2. Weeding, Transfer & Application
RESULT!
MISSION LOG: FINAL STATUS
The decal is perfectly adhered to the surface. The transfer tape removal was clean, leaving sharp edges on the vinyl. Mission accomplished.
The decal is perfectly adhered to the surface. The transfer tape removal was clean, leaving sharp edges on the vinyl. Mission accomplished.
Fig 5. The final result on the laptop lid
02. THE LASER CUT
The mission: Design a parametric piece that can be assembled in multiple ways. I chose to build a modular structure inspired by the X-Wing.
STEP 0: CALIBRATION (THE KERF)
Before designing the full ship, I had to find the "Magic Number". I created a test comb to measure the laser's kerf.
DESIGN
Designing the test piece.
MEASUREMENT
Measuring the perfect fit (Result: 0.20mm).
STEP 1: CAD ENGINEERING (SOLIDWORKS)
I designed the parts in SolidWorks using parametric variables. Here is the breakdown of the fleet's components.
PART A
Desingning the front part.
PART B
This is the Body Section.
PART C
Upper Wings Geometry.
PART D
I desing a part to connect the body and wings.
PART E
I used a connector to join the body and the front part.
PART F
To hold the body together, I designed a horizontal connector.
PART G
For the front part, I desingned a support piece.
PART H
Virtual Assembly Test.
STEP 2: BLUEPRINT & REALITY
THE DXF
Final DXF. This is how the laser "sees" the design. The kerf compensation is already applied to the slots.
THE PARTS
Fresh out of the machine. The MDF edges are burnt but clean.
STEP 3: LASER BEAM ENGAGED
FOCUS
Setting the correct height of the laser.
ACTION
Machine working, I used this configuration: Speed: 20 / Power: 60.
MISSION ACCOMPLISHED: THE FLEET
MISSION LOG: ASSEMBLY PROTOCOL
The moment of truth. I assembled the parts without a single drop of glue. Thanks to the kerf calculation (0.2mm), the friction holds the structure together perfectly.
The moment of truth. I assembled the parts without a single drop of glue. Thanks to the kerf calculation (0.2mm), the friction holds the structure together perfectly.
Video 2. Assembling the X-Wing (Time-lapse)
READY!
MISSION LOG: SQUADRON STATUS
The X-Wing is fully operational. The structure is rigid, the wings are locked in attack position, and the aesthetic is clean.
The X-Wing is fully operational. The structure is rigid, the wings are locked in attack position, and the aesthetic is clean.
Fig 6. Left View
Fig 7. Right View
03. CLASSIFIED FILES
05. AI CO-PILOT LOG
PARAMETRIC FORMULAS
"I used Gemini to understand how to set up Global Variables in SolidWorks for the slot thickness equation."