Week03 Computer-Controlled Cutting¶
Weekly Focus¶
This week focused on computer-controlled cutting, specifically:
- Laser Cutting
- Vinyl Cutting
- Parametric Design
- Press-Fit Construction Kits
The objective was to understand how parametric design techniques can be used to create adaptable designs that respond to material thickness and laser kerf.
Assignment Overview¶
The assignment required:
- Designing and fabricating a parametric press-fit construction kit
- Accounting for material thickness and laser kerf
- Producing a vinyl-cut design
- Documenting the full workflow
The laser cutter characterization and kerf testing were completed as part of the group assignment.
See group documentation: Group Assignment – Laser Cutter Characterization
Individual Assignment¶
Parametric Press-Fit Construction Kit¶
A press-fit kit is a construction system where parts connect without glue, screws, or fasteners.
The stability of the structure depends entirely on accurate slot dimensions and friction between parts.
To make the design flexible and reusable, I used parametric design techniques so that the slot width can be easily modified if the material thickness changes.
Parametric Design Method (this method is changed to Fusion360 parametric… Rico recommended to use as requirement in the assignment… I used it in the following)… just this was my error¶
Instead of manually editing every slot, I created a master notch in Inkscape (not allowed… this was my mistake … Using Freecad or Fusion 360 is allowed).
The workflow:
- Create a single master notch representing the slot width
- Place it on a separate layer called
Notch_Template - Generate slots using Edit → Clone → Create Clone
- Position slots using Align and Distribute
With this method:
- Changing the master notch width
- Automatically updates all slots
This is the core concept of parametric design.
Parametric Design Reference¶
Video used for learning the technique:
Inkscape Parametric Design Channel: Young Engineers Of Today
https://youtu.be/ErelrIJxZ6I
Key concepts demonstrated:
- Master notch creation
- Clone-based parametric design
- Align and distribute workflow
- Scalable parametric layouts
Clone setup
Clone control
Clone keys
Computer-Aided Design (Parametric Design with Fusion 360)¶
Assignment Overview¶
In this section of the assignment i focussed on parametric design using Autodesk Fusion 360.
The workflow was updated from Inkscape to Fusion 360 based on instructor feedback to achieve true parametric modeling.
The goal is to design a structure where all parts automatically update when a parameter is changed.
Software Used¶
- Autodesk Fusion 360 (Parametric CAD)
What is Parametric Design?¶
Parametric design uses: - User-defined parameters - Constraints - Feature relationships
This allows: - Automatic updates - Design flexibility - Faster iteration
Initial Setup and User Parameters¶
Step 1: Create Base Component¶
To maintain a clean design structure:
- Create a new Component named
Base - Work inside this component
Base Component Setup¶
Step 2: Define User Parameters¶
Go to:
Modify → Change Parameters
| Name | Expression | Description |
|---|---|---|
| thick | 3/8 in (or 3 mm) | Material thickness |
| notch_width | 3.2 mm | Slot width |
| notch_depth | 10 mm | Slot depth |
| slot_spacing | 20 mm | Slot spacing |
This allows global control of the design … shown at the final here
Parameters Setup¶
Start parametric goto modify toolbar and extend the drop down select change parameter
Base Construction¶
Step 3: Create Base Sketch¶
Base Sketch¶
- Use Center Rectangle (important for symmetry)
- Anchor it at the origin
Step 4: Extrude Base¶
Base¶
- Extrude using parameter:
thick
Parametric Side Design¶
Step 5: Create Offset Plane¶
- Go to:
Construct → Offset Plane - Set distance =
thick
This positions the side correctly
Offset Plane¶
Step 6: Project Geometry¶
- Press
P(Project tool) - Select base edges
Ensures alignment between parts
Project Geometry¶
Offset firs from the tools bar and select the xy plane on the purposed body
Step 7: Create Master Notch (Slot)¶
- Draw one notch using rectangle
- Apply dimensions:
- Width =
notch_width - Depth =
notch_depth
Master Notch¶
Step 8: Apply Constraints¶
Apply:
- Equal Constraint → uniform slots
- Midpoint Constraint → center alignment
- Collinear Constraint → edge alignment
Ensures stable parametric behavior
Constraints Applied¶
Step 9: Extrude Side (Parametric Formula)¶
Extrude using:
Total Height - thick
Keeps total height consistent
Side Extrusion¶
Mirror and Pattern Tools¶
Step 10: Mirror Side¶
- Use:
Create → Mirror - Mirror across origin plane
To avoids manual duplication i used the mirror tool
Mirror Tool¶
Step 11: Create Divider¶
- Project slot geometry
- Extrude up to top face
Divider Creation¶
Step 12: Rectangular Pattern (Component Level)¶
- Use:
Create → Pattern → Rectangular Pattern - Pattern type: Component
- Extent type: Extent
Distance formula:
Total Length - (3 × thick)
Ensures perfect fit automatically
Pattern Setup¶
Parametric Testing¶
Step 13: Modify Parameters¶
Test by changing:
- thick
- notch_width
Parametric Result¶
change only the thickness the main control for this parametric design
A with 3/8
A with 3/8
Visualization and Workflow¶
Step 14: Component Colors¶
- Go to:
Inspect → Display Component Colors
Helps distinguish parts visually and inspect with color for more clear work flow
Component Colors¶
Key Learning¶
- Parameters control entire design
- Constraints maintain geometry relationships
- Offset planes improve structure
- Projection ensures alignment
- Patterns automate repetition
- Mirror avoids redundancy
Comparison: Inkscape vs Fusion 360¶
| Inkscape Method | Fusion 360 Method |
|---|---|
| Clone | Rectangular Pattern |
| Manual align | Constraints |
| Static design | Fully parametric |
| Limited control | Parameter-driven |
Final result¶
Fusion 360 enables true parametric modeling, allowing full control over the design using parameters, constraints, and patterns.
This workflow ensures: - Accuracy - Flexibility - Easy modification
Learning Resources¶
Fusion 360 Parametric Design Tutorials [Fusion360 parametric tutorial]https://www.youtube.com/watch?v=zPzHMFK5ldk
Vinyl Cutting – Laptop Sticker¶
In addition to laser cutting, the assignment required producing a vinyl-cut design.
I created a FabAcademy logo sticker using the vinyl cutter.
Machine Used¶
C-48LX Contour Cutter Plotter¶
The C-48LX plotter is used for cutting vinyl graphics, decals, and labels.
C-48LX cutter
Vinyl Cutter Settings¶
| Parameter | Value |
|---|---|
| Speed | 200 mm/s |
| Force | 90 gf |
| Blade Offset | 0.25 mm |
Vinyl Design Workflow¶
- Download FabAcademy logo
- Import SVG into Inkscape
- Convert shapes to vector paths
- Prepare stroke-only design
- Export cut file
- Send to cutter using SignMaster
Bring the correct file Made the logo cuttable
Work on the Vector conversion of the logos
Vinyl Cutting Process¶
The vinyl cutter followed the vector paths to cut the design.
My Vinyl cutting process
Weeding Process¶
After cutting, the extra vinyl surrounding the design was removed manually.
Steps:
- Lift unwanted vinyl using a weeding tool
- Slowly peel away the excess material
- Leave the final sticker attached to the backing sheet
Weeding process with additional correction tools like scissor
Final Result¶
The finished vinyl sticker was applied to my laptop.
Design Files¶
Download the original design files:
- Press-fit kit design (SVG)
- Vinyl cutter file (PLT)
Download Design Files
Zib format
[Fusion360 parametric design]https://skfb.ly/pIIG9
Final Project Progress¶
This week helped me understand how laser cutting precision and kerf compensation affect mechanical joints.
The parametric design approach will be useful later when developing components for my final project.