Week 4: Computer Controlled Cutting

Parametric Design: Laser Cutter

As a fan of platonic solids I decided to do a Dodecahedron for my press fit kit assignment. I tried to use Autodesk Inventor to design but I discovered the settings were off and it was stopping my progress(as it did in week 3) so I changed to Fusion 360. It took a bit to get used to it, but soon enough I was back on track.

My first attempt was a heptagon with 60 mm sides.

HEPTAGON 01

After I sketched 10mm squares as the fitting pieces for the dodecahedron to hold together.

HEPTAGON 02 HEPTAGON 03

In the lab they use the corel software to make the machine work so I had to download Corel Draw.

COREL 04

Next I had to create a new project.

COREL 05

Following I imported my pentagon sketch which I exported from Fusion in a .dxf format and copied it 4 times setting it where I want the laser to cut the MDF(compressed cardboard) board.

COREL 07

Next I selected the cutting parameters:
- Speed: 30.0
- Power: 98
- PPI: 300

COREL 06

Finally I turned the extractor to avoid fumes and debri from floating around our breathing atmosphere and started cutting.

LASER CUTTER 01

I cut 4 of them and soon I found out there was a margin to consider due to the kerf (the space the laser incinerates when it passes) as the pentagons didn't generate enough friction to stay together (they were loose).
I discovered the KERF was 0.2mm so I got to it.

FAILED ATTEMPT

On the next attempt I designed a variable LENGTH = 40mm for the heptagon's sides.

HEPTAGON 04

Once this was done I segmented the side in 6 parts for the 3 rectangles and 3 spaces between them.

The adjusted dimensions were:
- 4mm long and (LENGTH/6 + 0.35mm) wide for the rectangles as the kerf was taking material from the rectangles reducing their dimensions.
- (LENGTH/6 - 0.7mm) for the spaces between them since the kerf was increasing their width. I laser cut 2 pentagons and they didnt fit so I adjusted the variables and did it again.

LASER CUTTER 02

The second attempt also failed but I was getting closer. On my final attempt the dimensions were:

- 4mm long and (LENGTH/6 + 0.1mm) for the rectangles.
- (LENGTH/6 - 0.2mm) for the spaces between them.

Finally, it fit and I had my dodecahedron as shown in the picture below (Next to the 2 results from the failed attempts).

DODECAHEDRON

Parametric Design: Vinyl Cutter

I decided to do a vectorized image of Zelda's Logo. I downloaded Corel X7 and once in I imported the picture of Zelda's Logo.

COREL 01 COREL 02

I found out there was an option to quickly vectorize any image on Corel. The commands to do so are: Bit Map>Quick Trace (My image shows the translation for this command). This option generates a vector image under the main image.

COREL 03 VECTORIZED ZELDA

Following this I removed the color of the vectorized image by Right Clicking it and then Ungrouping, following this I emptied the infill using the Interactive Infill Tool.

VECTORIZED ZELDA 01

Next, I selected the printer (Cutter) Roland GX-24 by pressing: control+p>preferences>Roland GX-24.

COREL 03

After I started the cuttting operation.

VINYL CUTTER

Once it came out I had to use a special tape to remove the sticker without breaking the pieces.

VINYL CUTTED ZELDA VINYL CUTTED ZELDA 01

Download the original files from the links below:
Pentagon Design: Fusion (.dxf file)
Vectorized Zelda Logo: Corel Draw X7 (.cdr file)


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