3. Computer Controlled Cutting¶¶

Week03 Summary: Laser Cutting and Vinyl Cutting Design

Main Objective:¶

This week, I completed assignments focused on both laser cutting and vinyl cutting. These tasks were aimed at understanding the use of these machines and how to create designs suitable for cutting. The assignments included both group and individual work:

Task 1: Group Assignment
Goal: Explore laser cutting by experimenting with different speed and power settings to determine the optimal settings for cutting various materials.
Task 2: Laser Cutting Individual Assignment
Goal: Design a press-fit object and use the laser cutter to manufacture it based on my design.
Task 3: Vinyl Cutting Individual Assignment
Goal: Use Silhouette Studio software to create a sticker design and then cut it using the vinyl cutting machine.

Learning Outcomes:¶

Throughout the week, I gained valuable skills and knowledge, including:

Mastering the use of laser cutters and vinyl cutting machines for precision design work.
Learning how to implement parametric design principles to create objects suitable for cutting.
Gaining an understanding of how to adjust laser cutting speed and power settings for optimal results on different materials.
Using Silhouette Studio for designing and cutting stickers, giving me a hands-on experience with the vinyl cutting process.

By the end of the week, I was more confident in using both laser and vinyl cutters and in applying parametric design techniques to my projects.

Introduction to Laser Cutting¶

Laser cutting is a highly precise and efficient manufacturing process that utilizes a focused laser beam to cut or engrave a wide variety of materials. This technique is widely used in industries such as automotive, aerospace, electronics, and fashion due to its ability to create intricate designs and achieve high-quality finishes. Laser cutting offers advantages like minimal material wastage, high repeatability, and the ability to cut through complex shapes with precision.

Below is an overview of the key aspects of the laser cutting process:

Laser Cutting Overview¶

Aspect	Details
Process	Uses a high-powered laser beam to melt, burn, or vaporize material to cut or engrave it.
Materials	Works with metals (steel, aluminum), plastics, wood, ceramics, textiles, etc.
Precision	Provides high accuracy, allowing for intricate and complex cuts with smooth edges.
Types of Lasers	- CO2 Lasers: Best for non-metal materials like plastics and wood. - Fiber Lasers: Ideal for metal cutting due to precise focusing and high efficiency.
Advantages	- High accuracy and repeatability - Minimal material wastage - Capable of cutting complex shapes - No mechanical contact, reducing wear and tear - Minimal thermal distortion
Applications	Automotive, aerospace, electronics, fashion, signage, and more.
Limitations	- Slower for cutting thick materials - High setup costs - Difficulties with certain materials (e.g., reflective metals)

Task 1: Laser Cutting Group Assignment¶

Group Assignment¶

This week, our group assignment focused on characterizing the key parameters of our laser cutter, including its focus, power, speed, rate, kerf, joint clearance, and various cut types. We conducted tests to analyze how each setting impacts the quality and precision of the cuts.

The complete documentation of the group’s work can be found on our project page:
Computer Controlled Cutting – Group Work

Individual Contribution¶

For this group project, I was responsible for documenting and explaining how to use the software to conduct the tests, as well as providing overall photo documentation. My role focused on ensuring that the process was clearly explained and well-documented for future reference.

Laser Cutting Optimization: Key Factors and Considerations¶

Optimizing key parameters like laser power, cutting speed, kerf width, and focus position is essential for achieving high-quality laser cuts. Below is a breakdown of each parameter and its impact:

1. Laser Power¶

Description	The energy output of the laser (in watts).
Impact	Higher power = Faster cutting, but may cause heat distortion and rough cuts.
Test Focus	Test optimal power for clean cuts without excessive heat or burn.

2. Cutting Speed¶

Description	The speed at which the laser moves (in mm/s).
Impact	Faster speed = less heat, but may cause incomplete cuts; slower speed = better cut quality.
Test Focus	Test ideal speed for balanced cuts and efficiency.

3. Kerf Width¶

Description	The width of material removed during cutting.
Impact	Power and speed affect kerf width. Too much power = wider kerf; too high speed = narrow kerf.
Test Focus	Test for consistent kerf width and dimensional accuracy.

4. Focus Position¶

Description	The laser's focal point location relative to the material.
Impact	Incorrect focus = poor cut quality and inconsistent cuts.
Test Focus	Test optimal focus for sharp, precise cuts and minimal heat-affected zone (HAZ).

Each of these parameters plays a vital role in ensuring optimal laser cutting performance. By adjusting and testing these factors, you can achieve the best possible cutting results.

Task 2: Laser Cutting - Individual Assignment¶

Parametric Construction Kit

For this assignment, I was tasked with designing a parametric press-fit construction kit that could be laser cut and assembled into various configurations. I began by exploring kits from previous Fab Academy students to understand their structure and gather design inspiration, particularly from Pinterest. Using Fusion 360, which I became familiar with last week, I applied parametric design principles to create my own kit.

The goal was to create components that could be laser cut and then assembled in different ways, offering flexibility and adaptability. I used Fusion 360’s parametric capabilities to define variables and constraints, allowing me to modify the design easily and ensuring the components could be reassembled into various forms after cutting.

Designing the Form¶

Conceptualizing the Design:

My goal was to create a form based on a dodecahedron, which could be scaled up into a geodesic dome or pavilion, and scaled down into a light cover. The design was intended to incorporate connections that are spaced enough to fit triangular panels, while also leaving gaps for light to pass through.

2. Creating the Design in Fusion 360¶

1.Creating the Hexagonal Base Shape:¶

I began by pressing Create Sketch and selecting a plane to start my design. Once in the sketch workspace, I used the Inscribed Polygon tool to create a hexagon. I chose the Inscribed Polygon option under the Create dropdown, setting the base dimension to 50mm. This allowed me to create a hexagonal component with six sides, which formed the foundation of the geometric structure for the design.

2. Drawing the Line and Creating the Circular Pattern¶

Next, I drew a line from one corner of the hexagon to the opposite corner by selecting Line under the Create menu. I then returned to the Create menu, chose Circular Pattern, and selected the center of the hexagon as the reference point. I set the quantity to 3 and pressed Enter to create three triangles around the center.

Afterwards, I kept one of the triangles to work on, deleted the remaining two, and used the Trim tool under the Modify menu. I double-clicked on the lines I wanted to remove to clean up the sketch.

3. Creating the Connection Point (Tab)¶

I then created a connection point on one side of the triangle by placing a line in the middle with a length of 5mm and offsetting it on both sides by 0.7mm to achieve an overall tab thickness of 1.4mm, based on the kerf test conducted in the first group task , which was performed on 2mm cardboard.

4. Creating Additional Connection Points (Tabs)¶

I created two additional connection points (“tabs”) by simply drawing a line in the middle of the rectangle, mirroring the first tab, and then trimming the extra lines to clean up the design. I repeated the process to create the second tab.

5. Adding Parametric Control to Tabs¶

-Select First Tab’s Width: Click the width dimension of the first tab and add a dimension.

-Rename Dimension: Go to Modify > Change Parameters. Rename the dimension to TabW for the tab width.

-Apply TabW to Other Tabs: For the second and third tabs, select their widths and replace the dimension with TabW.

-Test Changes: Adjust TabW in the Parameters dialog, and all tabs will update automatically.

6. Creating Connectors¶

-I created a rectangle for the first connectors with connectorLength (twice the tab length) and connectorWidth (5.5mm, larger than the tab width).

I then used the same method as above to create connection tabs within the connector. I drew a center line on the rectangle’s width with a value of 5mm, then offset it in each direction by 0.7mm, making the tab width 1.4mm. I connected the lines, trimmed the excess, added a line in the middle of the rectangle, mirrored the tab, and finally trimmed the extra lines.

-The second connector was angled by 120 degrees, resembling each interior angle of a hexagon. To create it, I drew a rectangle with a length of 12mm and width of 5.5mm. I then created another rectangle with the same dimensions, rotated at a 120-degree angle to the first rectangle. Next, I created a tab on the top part of the connector. The process for creating the tab was similar to the first rectangular connector as I added a line in the middle, offset it, connected the lines, and trimmed the excess.

The final step of creating the connections is to apply the same parameter for the tab width as the triangle above, ensuring that all tabs are connected. I did this by following the same steps of adding dimensions and replacing the value with TabW in the dimension box, ensuring that all the tabs were linked to the same parameter.

2. Saving the Shapes as DXF Files for Laser Cutting¶

Once all the shapes were completed, I followed these steps to save them as DXF files for the laser cutting machine:

I clicked on Finish Sketch to exit the sketching workspace.
I then extruded the shapes to give them depth.
After extruding, I clicked on the faces of the shapes and selected Trace Sketch.
From the Browser panel, I expanded the Sketch dropdown menu.
I right-clicked on the sketch that was created after the Trace Sketch operation and selected Save as DXF, and saved each shape individually as a DXF file.

These DXF files are now ready to be used by the laser cutting machine.

press fit kit v2 by Sarah on Sketchfab

click to download the press fit kit

3. Cutting and Assembling the Parts:¶

Powering on the Laser Cutter: I started by turning on the laser cutter by pressing the Start button located on the control panel. This powered up the machine and prepared it for the cutting process.
Preparing the Machine Bed: I opened the laser cutter’s handle and carefully placed the cardboard material onto the machine bed. I made sure the cardboard was aligned properly and flat to avoid any misalignment during cutting.
Launching RDWorks Software: I launched RDWorks software on my computer, which is the software used to control the laser cutter. Once opened, I imported the design file that I had previously created to send to the cutter.
Duplicating and Adjusting the Design: In the RDWorks software, I created a duplicate of the design to ensure I had a mirrored version for cutting. I rotated the duplicated design by 180 degrees to fit the cutting bed. Then, I clicked on the Parametric Library button to adjust the speed and power settings according to the material I was cutting (cardboard in this case).
Downloading the Design to the Cutter: Once the design was ready and adjusted, I clicked on the File button in RDWorks, selected the appropriate design file, and pressed Enter to send the file to the laser cutter.
Positioning the Laser Beam: After transferring the design, I used the arrow keys on the laser cutter’s control panel to move the laser beam and position it in an empty corner of the bed. This ensured that the cutting would start in a clear area, preventing any interference with other pieces.
Setting the Origin and Framing the Cut Area: I pressed the Origin button on the machine to set the starting point for the laser’s cutting path. After that, I pressed the Frame button to trace the cutting area and ensure the design would be within the machine’s working area. This allowed me to confirm that all parts of the design were within reach of the laser cutter.
Setting the Laser Focus: To set the correct cutting height, I used a Lego piece to locate the laser’s focal point. I placed my finger on the back of the Lego piece, placed it under the laser, and adjusted the height to ensure the laser beam was focused precisely on the cardboard’s surface for a clean cut.
Starting the Cutting Process: After ensuring the setup was correct, I pressed Start to begin the cutting process. Despite the correct speed and power settings, the shapes got littlie bit burned and some of it were dameged as they were placed close to each Other.
Final Adjustments and Assembly: Once the joint sizes were corrected, I cut a total of 20 pieces and began assembling them into different shapes. The pieces fit well, and I was able to complete the desired designs.

Failure attempt “The previous connection width was too short, making it unstable and unable to handle movement properly.”

Individual Assignment: Vinyl Cutting & Sticker Design in Silhouette Studio¶

1. Downloading Silhouette Studio Software¶

I began by visiting the Silhouette Studio website and downloading the software required to operate the Silhouette Cameo cutting machine. This program allows for precise design and cutting of shapes, including stickers.

2. Importing the Design¶

I selected a design file in DXF format that I previously designed in Illustrator and imported it into Silhouette Studio. This design served as the starting point for creating my sticker. The second time I attempted to import a JPEG file for tracing.

3. Tracing the Image¶

In Silhouette Studio, the DXF file opened directly without needing any further alteration. However, the JPEG file required tracing. I opened the Trace Panel, selected the area around the design, and clicked the Trace button to convert the image into a vector format. After tracing, I deleted the original JPEG image to keep only the vectorized design.

4. Aligning the Designs¶

I aligned both the imported design and the traced image to the corner of the canvas. This positioning ensured efficient use of the cutting space, maximizing material usage and avoiding waste.

5. Coloring the Design¶

I selected both the original design and the traced image and applied the same color to both. This step was crucial for clarity and ensured that the design would appear as intended when cut by the machine.

6. Preparing for Cutting¶

After finalizing the design, I clicked on the Send button to move on to the cutting settings. I adjusted the force and speed settings in Silhouette Studio to ensure the cutting machine would cut through the material smoothly without tearing it.

Preparing for Printing:¶

1. Adjusting Blade Depth¶

I prepared the Silhouette Cameo by adjusting the blade depth according to the material I was using for the sticker. I inserted the blade into the machine and rotated it to the appropriate setting to ensure clean cuts on the material.

2. Securing the Sticker Sheet¶

I placed the sticker sheet onto the cutting mat and secured it with tape to prevent any unwanted movement during the cutting process. This ensured that the cuts were precise and helped avoid any misalignment.

3. Loading the Cutting Mat¶

I pressed the Load Cut Mat button on the machine to hold the mat in place. I carefully aligned the mat with the machine’s cutting path to ensure that the material was correctly positioned for the cut.

4. Starting the Cutting Process¶

Once everything was aligned and set, I clicked the Send button to begin the cutting process. The Silhouette Cameo started cutting the sticker design as defined in the software.

5. Unloading the Mat¶

After the cutting process was completed, I pressed the Unload button to release the cutting mat. This allowed me to easily remove the sticker sheet and check the cuts for any errors.

6. Cutting Out the Sticker¶

Once the mat was unloaded, I carefully cut out the area around the sticker, leaving a small border around the design to give it a clean and finished look. During the initial cut, I realized that the force settings were too low, which made it hard to remove the stickers cleanly. To fix this, I increased the cutting force and performed a second pass over the design to ensure the cuts were deep enough to separate the sticker from the backing sheet.

7. Applying a Transparent Sticker¶

After the cutting was completed, I applied a transparent sticker over the design to protect it. This also helped remove any excess material around the edges, giving the sticker a professional finish and ensuring it adhered well to surfaces.

8. Final Result¶

After successfully cutting the stickers and applying the transparent cover, I was able to place them on my laptop. In the end, I successfully created three different sticker designs, each with clean cuts and smooth edges.

Last update: November 28, 2024