Week 3 > Computer Controlled Cutting¶
Group Assignment¶
by Charles Wangara
Lab safety training¶
User Safety flux 3D Information
All personnel who will operate the machine should read the saftey precautions and follow the instructions. Children require supervision and assistance of adults all the time.
Safety Switch: When the cover is opened, the safety switch will interrupt the device’s operation and stop the laser output. If the device does not stop operating when the cover is opened, turn off the power, cease operation, and contact customer service immediately. Even though the device is equipped with a safety switch, avoid placing your hands, eyes, or other body parts near the laser operation area to prevent accidents. When adjusting the optical path, ensure that you close the cover before testing to prevent burns caused by a failure of the safety switch. Do not operate the machine if the safety switch is malfunctioning. Do not attempt to disable the safety switch.
Work Environment: Place the device on a stable surface to prevent it from tipping over; it should not be overhanging or unstable. Set up the device indoors in well-ventilated areas with windows. Do not place the device outdoors, in basements, under metal roofs, or in other confined spaces. Connect the device’s ventilation hose to the outside. In case of rain or extreme weather conditions, turn off the machine and bring the ventilation hose inside. Ensure the device is stored at a temperature between 5°C and 40°C and humidity between 10% and 75%. Maintain the working environment at 5°C to 25°C (the requirement is reduced to 5°C to 30°C if the performance is below 40%). Do not place liquids, flammable, or explosive items near the device. Children should not play or run around in the area where the device is located.
Ventilation:
Connect the ventilation hose to the outside or an exhaust system to ensure the exhaust does not affect neighbors or public spaces.
If you notice a strong odor or heavy smoke, stop using the device immediately. Ensure the ventilation hose is properly connected and the ventilation system is functioning correctly before resuming use.
Power and Cables: Verify whether the operating voltage of the ordered model is 110V or 220V. Ensure the third hole of the outlet is grounded. If grounding is not confirmed, static interference may affect performance and increase the risk of electric shock. If you find the power cable damaged, stop using the device immediately. Always turn off the device and unplug it when cleaning, maintaining, or disassembling internal parts with FLUX’s approval. Do not allow cables and plugs to become damaged, lie near heaters, or be bent, twisted, pulled, or burdened with heavy objects.
Fire Hazard: Regularly clean the debris under the device’s honeycomb table. If a flame appears on the engraving material during laser operation, immediately turn off the device, unplug it from the back, and extinguish the fire with a wet towel. Note that water can cause irreversible damage to the device. For larger flames, use a fire extinguisher. Be aware that dry powder or foam from the extinguisher can cause irreversible damage to the device. If the flame is uncontrollable, call the fire department immediately. Do not use materials unsuitable for laser processing—refer to “Material Tips - Hazardous Materials” for more information. Do not stack materials in the machine, such as attempting to cut multiple boards at once. Do not leave the machine running unattended.
Setting up the laser¶
During the setup i used this manual
NOTE - Never leave the lasercutter unattended and unobserved when it is cutting…in case a fire begins - In case of fire, first turn off power to the lasecutter then use fire suppression devices to put out the fire immediately
Engraving,speed,power¶
Raster engraving is a laser engraving method where the laser moves line by line across an image, similar to how an inkjet printer works, allowing grayscale images and filled areas to be engraved. In this test, an image was imported into Beam Studio and engraved on paper using the FLUX Beambox to evaluate how power and speed settings affect engraving depth and clarity.
Four tests were performed.
| Test | Power (%) | Speed (mm/s) | Result / Observation |
|---|---|---|---|
| 1 | 30 | 300 | Very light and shallow engraving; insufficient energy |
| 2 | 60 | 300 | Clear engraving with moderate depth |
| 3 | 60 | 150 | Darker and deeper engraving due to longer exposure |
| 4 | 90 | 150 | Very dark engraving; risk of cutting through material |
For raster engraving, higher speed reduces engraving visibility, while higher power and lower speed increase burn depth. A medium power with moderate speed provides the best balance between engraving clarity and material safety.
Vector Cutting,focus, Kerf¶
Kerf Measurement
Kerf is the amount of material removed by the laser during cutting and must be measured to ensure accurate dimensions and proper press-fit joints. To measure the kerf of the FLUX Beambox, a vector design was used, since kerf measurement requires precise vector cutting rather than raster engraving.
Before cutting, the laser was manually focused because the machine does not support automatic focus. The focus was set by loosening the focus mechanism and adjusting the honeycomb bed height until it touched the acrylic workpiece. This ensured the laser was correctly focused on the material surface.
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Kerf Test Design
Three circular test cuts with different diameters were designed. For each test, the designed diameter, measured hole diameter, and measured cut-out piece were recorded. The kerf was calculated as:
Kerf = (Hole diameter − Cut piece diameter) / 2
Kerf Test Results
| Test | Designed Diameter (mm) | Measured Hole (mm) | Cut Piece (mm) | Kerf (mm) |
|---|---|---|---|---|
| 1 | 20.0 | 20.3 | 19.6 | 0.35 |
| 2 | 30.0 | 30.4 | 29.5 | 0.45 |
| 3 | 25.0 | 25.2 | 24.8 | 0.20 |
Kerf Calculation
The average kerf was calculated by summing the kerf values and dividing by the number of tests:
Average kerf = (0.35 + 0.45 + 0.20) / 3 = 0.3333 mm
Learning Outcomes¶
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POWER and SPEED settings are different for different materials…this is true of engraving too
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Understood the function of the safety switch and why the machine must never run unattended.
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Set up and manually focused the FLUX Beambox laser cutter.
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Performed raster engraving tests to analyze the effect of power and speed.
Learned that:¶
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Higher power + lower speed → deeper/darker engraving
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Higher speed → lighter engraving
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Conducted vector cutting tests to measure kerf.
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Calculated kerf using: Kerf = (Hole diameter − Cut piece diameter) / 2
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Determined the average kerf ≈ 0.333 mm.
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Understood the importance of kerf compensation for accurate press-fit joints.
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Recognized that power and speed settings vary depending on material and operation type (engraving vs cutting).