Assignment

1-Group assignment

Characterize your laser cutter, making test part(s) that vary cutting settings and dimensions

2-Individual assignment

Cut something on the vinyl cutter design, lasercut, and document a parametric press-fit construction kit, accounting for the laser cutter kerf, which can be assembled in multiple ways

1-Group assignment:

Materials available:

• 3mm MDF -which happened to be of 3.17 mm after measuring it accurately with the calliper
• 5.5 mm MDF

We have used the 3.17 mm MDF
For cutting, the power of the laser cutter should always be 100; it varies for engraving
Machine used: Laser Cutter – Epilog Fusion M2

• Work area: 500mm x 800mm
• Materials: wood (12mm), glass, cork, leather, cardboard, paper, fabrics, non-PVC acrylics, and other organic materials (up to 13mm)
• File type: AutoCad, JPG, and BMP for raster
• Power: 120 Watts

Fusion Series Suggested Material settings for Speed, Power and Frequency

We calculated the kerf of our laser cutter via two types of tests:

1) First Test:

Objective: Select the best cutting settings in terms of speed, power, and frequency. In the case of wood, the frequency should be the lowest (10). Cutting speed needs to be determined in order to have the smallest kerf.

Method: Cut multiple lines with different speed settings around the reference speed provided by the manufacturer’s specifications. Observe by eye at which speed the material is fully cut. The first fully cut line should be the finest cut, thus the smallest kerf.

1) Second Test:

Objective: Measure the kerf for the setting previously selected.

Method: Cut one or multiple segments with the same setting. Measure the length of the outer frame, measure the length of the adjacent cut segments, divide the difference by the number of cuts. The result is an estimation of the kerf. We made two tests with different layouts to get an average.

How to apply tests

1) First: Drawing a test layout

• Draw a layout on a vector type CAD (we used AutoCAD). Make sure there is no line superposition to avoid cutting the same line twice. The lines that should be cut in a single cut with same parameter should be joined into one line. (Click ‘Ctrl + A’ then ‘Join’)
• Save as DXF
• Import DXF file in Corel Draw. Make sure all the lines are hairlines (hairline will be cut; other lines will be engraved). Place the drawing in top left corner.
• Open the laser cutter properties window (Ctrl + P for printing the job). In the general tab select vector job type, select top left corner for positioning, enter machine bed dimensions (800x500 mm for our machine)

2) Second: Colour mapping (for Test 1 only):

• Colour mapping helps in feeding different settings for each different line, so that the laser cutter understands that it should not cut all the lines in the same way or speed
• In Corel Draw, colour each line with a different colour and note the RGB of each colour.
• In the laser cuter properties window, open the colour mapping tab, copy the RGB previously noted and assign cutting parameters for each colour, specifying speed, power, and frequency (in %).
• For wood, the power will remain at 100%, and the frequency at 10% according to the manufacturer’s specifications. So in this case only speed will vary.
• According to manufacturer’s specification, the reference speed value for wood is 40%. So the speed setting will have to range around this value.
• Select vector and deselect raster to cut and not engrave (it shouldn’t make a difference if all the lines are hairlines).

3) Third: Operating the laser cutter.

• Turn on the machine, then load the file to the laser cutter by clicking print. From there, the work is on the laser cutter interface.
• Position the wood board on the laser cutter metal bed. Then place the gage tool to calibrate the focal point of the laser on the right z value. When the gage touches the board, zero z. Then move the laser cutter head to the starting position and zero xy.
• Before starting, make sure that the compressor is turned on, as well as the extractor, to enable air flow to evacuate the fumes and prevent fire risks and toxic fumes inhalations.
• Start cutting, and supervise the machine till the job is completed (the laser cutter should not be left without supervision while operating).
• Once the job is done, wait for fumes to be fully evacuated before removing the board.

TEST RESULTS

1) First test: The best cut appears to be between 28 and 30% speed

2) Second test:

i) Evaluation of the kerf for speed 29%

• Test 2A: Kerf = (33.45 - 33.27) / 2 = 0.090
• Test 2B: Kerf = (100.28 - 99.25) / 11 = 0.094

i) Evaluation of the kerf for speed 30%

• Test 2A: Kerf = (33.81 – 33.73) / 2 = 0.04
• Test 2B: Kerf = (100.34 – 99.88) / 11 = 0.042

2-Individual assignment:

For the press-fit kit construction

I wanted to make some accessories that I can wear especially that I am fashion driven so I was trying to really enjoy this assignment

I did not have previous experience with Fusion360 in order to draw a parametric design. So I thought of keeping it simple while being inspired by the Bauhaus and De Stijl movement and use basic geometrical shapes: a square, a triangle and half of a cercle.

I have also added a curve so that it can help me in designing my necklaces.