3. Computer-Controlled Cutting
This week we learned about parametric design and its application to computer-controlled cutting, principally in laser cutting and vinyl cutting.
Laser Cutting
Laser cutting is a thermal, non-contact process that uses a high-powered, focused laser beam. It is normally used to engrave and cut different kinds of materials, like metal, plastic, or wood. It works thanks to a CNC (Computer Numerical Control) software, which indicates the digital pattern the laser beam must follow. While the beam traces the path, a coaxial gas jet (oxygen or nitrogen) blows away burnt material, leaving clean, finished edges.
At Fab Lab Puebla, we have 3 different laser cutters from CAM Five: the CFL-CMA1200,
CFL-CMA1080K, and CFL-CMA 1309T. To learn more about them and laser cutting check the
Machine & Setup
Here is how I configured the CFL-CMA1080K laser cutter:
Set Up
In this diagram we can see the principal components of laser cutters in general.
Followed the three CAM Five laser cutters available at Fab Lab Puebla.
1. Check that the machine chiller is on — it regulates the machine temperature for a safe workspace.
2. Turn on the automatic voltage regulator.
3. Turn on the machine switch and release the safety button.
4. Insert the key, turn on the laser, and move it to max.
5. Final step — machine fully ready for operation.
The origin is normally at the top right corner, but it can be repositioned using the panel control arrows followed by the origin button.
Parametric Kit – Card Game Box
For this exercise I designed a box for card games in Onshape. This box uses a flexible hinge, finger joints, and a sliding locking mechanism based on "Flexible book boxes" I found on the internet and Pinterest.
All cut pieces laid out — ready for assembly.
Hero shot of the assembled card game box.
Shape Design Process in Onshape
I modeled all pieces in Onshape using parametric variables. Here is the full design process step by step.
1. Created a new document (Week 03), started a sketch on the Top Plane, and drew a rectangle with rounded vertices using the fillet tool. Variables were created with the # symbol when dimensioning.
2. The variable table — I tried creating one just like in SolidWorks, but two variables gave "error regenerating." The flex hinge first attempt also snapped on a quick laser test.
3. After researching, I found a YouTube video with flexible hinge samples and bending radii. A 1 mm distance worked perfectly. I drew 4 lines per section and used a linear pattern.
4. Used the "Sheet metal model" tool to apply a bend on the center line of the flex hinge, which lets me visualize the folded result in 3D.
5. Used the "Use" tool (u) to reference the finger holes of the book paste, drew the front piece rectangle with height = thickness and length = (thickness×2)+(kerf/2).
6. Added a slot for the sliding mechanism, used trim (m) to remove extra lines, then extruded the piece.
7. Continued modeling the remaining pieces using the same logic — drawing joints based on previous pieces and assigning sizes from existing variables.
8. For repeated sides I used the 3D linear pattern tool, assigning the length of the piece. This step can be skipped if you don't need the 3D model with all pieces.
9–10. Continuing the assembly of all box sides, referencing previous pieces at each step.
The sliding mechanism has 5 pieces: a base, sliding bolt latch, slot guide, and 2 connecting pieces.
Exporting the DXF files. Right-click the face of each part and select Export DXF. Use DXF format, version 2000, in millimeters.
All exported files ready. I exported them separately so I can re-export only the piece that changes when I update a variable.
Vinyl Cutting
Vinyl cutting follows the same CNC logic as laser cutting, but instead of using a focused beam, it uses a knife. For this exercise I used the VersaSTUDIO GS2-24 from Roland and the Cut Studio software.
Machine & Setup
Before sending the file, the vinyl cutter must be loaded and ready. We used a full vinyl roll secured with clampers.
The VersaSTUDIO GS2-24 from Roland and the Cut Studio software interface.
1. Load the vinyl roll — we used a full roll since there were no scraps available.
2. Secure the roll using the clampers. Pull the handle to lock the material — if not secured, it may shift and cause cutting errors.
Machine control panel — pen force and origins were already configured for this exercise.
Machine fully loaded and ready to receive the cut file.
Learning Outcomes
This week strengthened my understanding of the relationship between digital precision and physical material behavior.
- Kerf is measurable, not hypothetical: Before this week, I only considered "small tolerances" without actually measuring kerf. Learning how to calculate it precisely changed my approach to joint design and assembly accuracy.
- Laser parameters directly affect quality: If parameters are not calibrated correctly, the machine may not cut through the material or may burn it excessively. Testing speed and power combinations is essential for clean results.
- Lab safety training is essential: The laser cutter requires strict safety protocols. I learned about ventilation systems, fire risks, material restrictions, and the importance of never leaving the machine unattended. Understanding which materials are safe to cut and which release toxic fumes is critical.
- Material behavior matters: Warped material, thickness variations, and incorrect focus can compromise the final piece. Not all errors come from the design — some may come from setup conditions.
- 2D design for fabrication: I also learned that 2D design can make 3D objects — for example the flex hinge pattern, where distances and design directly affect bending angles and results.
- Vinyl cutting as a complementary process: The vinyl cutter follows a similar CNC logic to laser cutting. It can be used to customize and finish projects, adding an extra layer of detail.
I will apply this knowledge in future projects that require press-fit systems or modular assemblies. Measuring kerf instead of guessing tolerances will now be part of my workflow for laser cutting.