Week 3 : Computer-controlled Cutting : Laser Cutting

💡 Note: You can find the project files here

For this week, I wanted an assignment I would be proud of, so I decided to make a car using 3 mm MDF.

Select a reference image

I did not have a clear idea of the car dimensions, so I selected this photo from the internet as a reference.

Generate a 3D model

The 2D reference image was not enough to know the exact dimensions, so I decided to create a 3D model based on the reference image. I used Meshy AI, which gives free download options for 3D models generated by the Meshy 4 AI model for a limited time, which was enough for me.

Here is the 3D model generated by Meshy AI.

Meshy_AI_ Gray_ Pickup_ Truck_generate by malak-alsharqawi on Sketchfab

Drawing the 3D model

I used Fusion 360 to draw the 3D model and generate the 2D drawing for each part of the car.

Here is the 3D model from Fusion 360.

Car_fusion360 by malak-alsharqawi on Sketchfab

I had to convert my model from 3D to 2D for the cutting process. So I projected the 3D model onto 2D planes to create the necessary cutting paths. Then I put the 2D projections in one file to get ready for the cutting process.

💡 Note: I used Inkscape in the beginning to do the 2D drawing, but I faced some problems with it, so I decided to use Rhino, which was much better and easier for the 2D drawing.

Then I imported the 2D drawings into Trotec software to cut them using the laser cutting machine.

I used the Trotec laser cutting machine to cut the parts of the car from 3 mm MDF.

Then I cut a test for the slots to make sure that the dimensions were correct and the parts would fit together.

Here is the cutting process.

After I chose the best dimensions, I proceeded with the final cutting process. I edited my 3D model based on the test results to make sure that all the parts would fit together perfectly. I took advantage of the parametric design, so I changed all the slot dimensions with one small change. Here is my parameters list.

Then I cut all the parts of the car.

Week 3 : Computer-controlled Cutting : Laser Cutting

1. Idea

For this week, I wanted an assignment I would be proud of, so I decided to make a car using 3 mm MDF.

2. Design

I did not have a clear idea of the car dimensions, so I selected this photo from the internet as a reference.

The 2D reference image was not enough to know the exact dimensions, so I decided to create a 3D model based on the reference image. I used Meshy AI, which gives free download options for 3D models generated by the Meshy 4 AI model for a limited time, which was enough for me.

Here is the 3D model generated by Meshy AI.

I used Fusion 360 to draw the 3D model and generate the 2D drawing for each part of the car.

Here is the 3D model from Fusion 360.

3. Prepare model for cutting

I had to convert my model from 3D to 2D for the cutting process. So I projected the 3D model onto 2D planes to create the necessary cutting paths. Then I put the 2D projections in one file to get ready for the cutting process.

Then I imported the 2D drawings into Trotec software to cut them using the laser cutting machine.

4. Cutting process

I used the Trotec laser cutting machine to cut the parts of the car from 3 mm MDF.

Then I cut a test for the slots to make sure that the dimensions were correct and the parts would fit together.

Here is the cutting process.

Then I cut all the parts of the car.

5. Assembly

After cutting all the parts, I started to assemble the car.

Here is the final result.