Posts Tagged ‘laser cutting’

Assignment: to do the press-fit smth

Software: Rhino 5, LaserWorks

Equipment: Laser Cutting Machine

Material: 4mm plywood

I started with an idea to make something simple and at the same time functional. Thus, I decided to make an iPhone stand, which could be useful on daily basis. 

I sketched a laconic design consisted of 3 pieces. The angle of the main surface provides convenient usage of the device. It is easier to type, scroll and swipe through content and, last but not least, enables to unlock your phone through face ID without picking it up.

Further, I made a precise drawing of the stand in Rhino 5, which is compatible with a software for laser cutting machine (LaserWorks).

After cutting out the whole thing and trying to assemble it, I found out that press-fit joints are not tight. Apparently, this happened because of the machine’s possible errors. Gaps should have been smaller, while reply part, conversely, wider. Because I did them equal, I had to use a glue to fix this mistake.

↑↑↑(Btw, the ‘less is more’ logo is quite important here – it represents the whole concept :D) 

Eventually, I managed to get it all together and there it is in use!

Team Members

Julia Baystrukova, Andres Gomez, Renata Abdrafikova

Assignment

To construct the highest tower possible using press-fit technology with following limitations:

  • Only three types of elements are available, each not bigger than 150mm x 150mm.
  • The size of the plywood sheet available for cutting is 900mm x 600mm.

Software / Materials

  • AutoCAD
  • Rhino 6
  • Laser Works
  • Plywood

Machine

  • Laser cutter

Sketching & Drawing

To develop a design we started by sketching our ideas, at first each member of the team proposed a design. From the three of them we choose the one we thought it was going to be the tallest and the most stable.

After having the design on paper we took it to a drawing software in order to make the design more precise.

Cutting

During the production of pieces we faced a problem:

It took us some time to adjust the laser itself for a precise cut. We changed the speed and the power of the machine a few times, but still, we weren’t satisfied with the result.  Only after adjusting the focus of the laser we managed to get a fine incision without burning plywood.

Construction

For joints we left the space of 3mm, while the width of the material was 3,9 mm. This made or joints quite tight, but we had to widen some gaps with a rasp and attach them with a help of a small hammer.

We managed to make our tower as high as the ceiling height in our lab. But, unfortunately, it was standing only because the construction abutted the ceiling.

Final Result

That is why the design of the tower deviated from the original plan during construction.

In the basement we changed 45-degree trotters to 90-degree and connected them at the bottom. This solution gave our tower more height in the basement part and, of course, more stability. In the upper part we managed to balance it with a square element. It was still leaning to the side but stood properly.

At the end, even though it was not as high as the first variant, we managed to get more or less stable construction.

Research Seminar Technology

Machine: Laser Cutting Machine

Software: AutoCad

Material: Playwood 3.7mm

Limitations:  10*10 cm, Press fit model

Goal

Use Laser Cutter and it’s sofware

Learn New software (Rhinoceros, Autocad, etc.)

Look for some inspiration on the web (external references)

Step 1

Look for some references on the web (Google, pinterst, etc), sometimes ideas don’t come at the very first time and you can get them everywhere.

Step 2

Start working on the idea, in order to make your idea come to life, do some sketching, remember “Less Ketchup more Sketchup”

Step 3

What are you waiting? once you have the idea and your drawing you to the nearest laser cutter machine and bring to life.

[Rember always use the correct safety gear and be as careful as you can]

Step 4

It’s alive! now finally done, cut and ready to test it.

As you can see the final result worked as it was supposed to do, but remember to be careful at the time of laser cutting, always check the power and the speed of the machine this will be really useful to make sure you cut is perfect and you don’t have a low quality result, also always have in mind the dimensions of your creation, sometimes they can be tricky at the time of cutting.

Remember master make perfect, sometimes things don’t come up like they are supposed to be at the very first try, keep practicing and become a Laser cutting Jedi.


Este obra está bajo una licencia de Creative Commons Reconocimiento 4.0 Internacional.

Sleigh

Class: Technology

Machine: Laser cutting Machine

Software: Rhinoceros

Material: Plywood (4 mm approximately)

Limitations:  10*10 cm, Press fit model

Goals:

  • Learn How to use Laser Cutter
  • Learn New software (Rhinoceros, Autocad, etc.)
  • Find out what is Pinterest

Process:  

First of all, the question was what to do. As it was mentioned in the previous class Pinterest is very useful to find inspiration, I decided to start from there. Honestly, it wasn’t really useful. 

So next, after some days of straggling for a masterpiece, I decided not make things difficult and did something that first came to my mind. It was a sligh.

I haven’t done any sketches of my future project, and I have to agree it was a mistake (I will explain it below). So I decided to start drawing in Rhino cause it was the only software I somehow knew. The 2D model looked like this:

As you already can see I made a mistake. the longest pieces don’t have enough holes. 

Then I exported the file to .dxf format and sent to laser cutter, Than was my second mistake: I didn’t make any photos while it was cut. 

After I assembled it, it looked like this:

Because the construction is modular you can do pretty many things with it only using your imagination. For example, Bookshelf with the ladder (special thanks to Andy, that is his idea) :

Results:

I learn some basics of laser cutting, 2D drawing. I made some mistakes, which were crucial for my project. However, if you use some creativity you can make quite interesting things with the material you have.

https://drive.google.com/drive/folders/1mDIslg1OT7_0EaRrNF5kWH-0BVP0OYMQ?usp=sharing

Class: City and Technology 1st year

Software: Rhino 6

Material: Plywood

Machine: Laser cutter Raylogic AS-1290C

Challenges:

  • learn how to use Rhino 6;
  • create a useful item
  • size of the item should be not bigger then 10cm x 10cm;
  • learn how to make press fit models
  • learn how to use the laser cutting machine

Idea: The primary goal was to create an item, which will be used at home. At the start, the idea was to create a photo frame with lightning inside. However, some changes were made during the process. In the end, the napkin holder was created.

Preparation: Due to the lack of experience in creating items the first step was to create cardboard maquette. All details were fit, so drawing was made in the Rhino 6.

The second step was to cut designed item by using the laser cutter. Due to the miscalculation, the first problem appeared: side detail did not fit. Connector on the side detail was not deep enough to feel for the squire details. So, the redesign was needed.

Was decided to make the connectors deeper. The final side detail is shown below. The two samples were cut to test the connection.

Finally, details of the item were able to connect without glue, and the item reminded the napkin holder, moreover napkin holder is more useful then photo frame.

DXF files available here: https://drive.google.com/drive/u/2/folders/1N9OradPhlWxXaa1D4xKIsDUjn4-mJ1BJ

Class: Technology

Machine: Laser cutter

Software: Autocad 2018, Rhinoceros 5

Material: Plywood; thickness: 3,6 mm

Size of the object: 30*25*14 cm

Challenges:learn how to work with laser cutter, how to use AutoCad 2018 and use correct scale in Rhinoceros 5

TASK | APPROACH

The 1sttask was dedicated to creation of own press-fit projects using plywood details of 10*10. Core idea was to familiarize students with software used and get first experience with laser cutting objects.

As advised on the class I dived into Pinterest to find a good idea. My attention was drawn to a simple though practical laptop stand and I used this concept to do one of my own. 

https://drive.google.com/file/d/1fu_UQyQPE7z9_lP4wyf53MA8XUvmGJ99/view?usp=sharing

It’s ready to use.

CLASS – TECHNOLOGY, LASER CUTTING

SOFTWARE: Rhino 6, LaserWorkV6

MATERIAL: Plywood 100*100*4 mm

MACHINE: Laser Cutting Machine Raylogic AS-1290C

CHALLENGES: Create something press-fit


TASK / PREPARATION

The task sounded quite simple: create something pressfit using plywood. This task had a goal to develop our skills in Rhino and Laser cutting.

As far as we had only one material and small size of this material, I decided to make a two-sided keychain to make people on the streets happier. I had an idea to write something inspirng, which ended in “Hey, You! Smile ;)”.


DESIGN PROCESS

The sketch of the key chain came into my mind in the metro, so I decided not to waste my time and draw it in Rhino.


LASER CUTTING

After saving my file in .dxf format I passed to the computer, which is connected to the Machine. I open the file with “File – Import” and placed it on the “surface” of the Laser Cutter.

I had to make two layers:

  • general layer of cutting (Speed 9mm/s; Power 95.0);
  • layer for “printing” (Speed 200 mm/s; Power 30.0).

First layer cutted the key chain itself, second one was slightly burning the plywood to “print” the letters.

“Printing by Laser cutting machine”

Because of the problems with the machine, I had to cut it twice. Because of that, the size of connecting sticks was smaller than the holes. I had to use glue to connect it.


RESULTS & REFLECTION

As a result of the work, I created a key chain, which is actually is not a press-fit thing. The idea itself was not a press-fit from the start.

Laser cutting is a simple and cheap (materials) technology to create prototypes.

The task allowed me to understand the main principles of working with Rhino and the laser cutting technology itself.

As an overall result, I can now give people another reason to smile, when they see my key chain on the backpack.


Scope of the Assignment:

Assignment II is an assignment in which we were to make items of our choosing using the basics gained 
up to that point in time, these being the laser cutting process as well as the basics of press-fit.

Inception:
The process of 3D printing is fast gaining popularity especially with regards to prototyping where it has become a must have component if one is to make a prototype. Having a prototype printed out is essential to the process of design since it helps to actually feel and see the item being prototyped. In anticipation of various items to be used in the "City Project" field, I chose to focus prototyping on components related to the "City Project"

Troubleshooting:
Duration of 3D printing Process.
Depending on the complexity of the item being printed, the process can either take just a few minutes, to several hours.
Iterations 1 - 3 of Palm bracelet along with knuckle ring component

Model of Component – Palm Bracelet

The modeling of the above captioned palm bracelet was subsequently instrumental in determining the ridiculousness of our initial assumption both in terms of utilitarian inconveniences as well as ease of use, not to mention the fact that it just failed to serve its purpose. Subsequent modifications forced the team to think more organically. This hands on approach enabled the team to acknowledge and understand the scope and limitations of the technology in use. Depending on the task at hand, I was able to optimize and subsequently better choose the means with which to make each respective prototype component.
This outside the box approach to the prototype (heck, the box was thrown out entirely) was one of the issues in that it presented a steep learning curve to me personally. 
The optimization of the design is enhanced by the fact that the item becomes tangible and it can be tested (if printed to scale). This is one of the few shortfalls of the virtual environment and simulations in CAD software as a whole. 
The printing process is also limited by the dimensions of the printer used. For instance, the Ultimaker 2 Go has a build volume of 120mm x 120 mm x 115mm. 

Materials Used:
Printing was done on Ultimaker 2 Go, using PLA (Polylactic Acid) which as it turns out, is one of the more commonly used 3D printing materials. The model was saved in STL format and was prepped for printing using Ultimaker Cura.

Ultimaker 2 Go

Lessons Learnt:
The prototyping process is made much easier with the use of 3D printers.
The choice of materials (of the prototype) should be taken into consideration during the printing process.
The use of a resin laser 3d printers is a more accurate method of 3D printing.

TOWER – GNM

Assignment Parameters:
The assignment was to construct a tower using press fit laser cut modular pieces with a dimensional 
limit of 150mm on the length. 

Materials:
Modular patterns were restricted to 3 patterns or modular units.
Laser Cut plywood

Modular Units for Tower Structure

Pre-Design - Conceptual approach:
The concept was based on attainment of the maximum height without compromising the structural 
integrity of the tower frame. with these two parameters as the basis, it was evident that 
additional stability could be attained by the use of a cross-pattern of "beam" structures. 
Horizontal elements were left out. 

Iterations and Re-Design:
In line with the initial concept of simplicity, there were few iterations between the initial 
design and the final version.

Assembly of Tower

Fully Assembled Tower

Troubleshooting:
The initial design had stability issues due to the initial proposal of framing the beams using 
continuous interlocking. This made the initial design heavy. Whereas the interlocking pattern 
was maintained for the base in order to keep the structure stable, the interlocks were discarded 
at the subsequent upper levels, making the structure lighter and allowing for attainment of 
increase height.

Cutting & Assembly:
Cutting out of the modular units was done using a laser cutting machine.
The cutting process took about 45 min.

The Team

Credits:
Whereas the final product was a product of active team work on the part of all team members, 
the cutting work was conducted under the guidance of the course supervisor Ivan Mitrofanov 
since at the time non of the team members could conduct the cutting works independently.

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(metro stations ‘Lubyanka’ and ‘Kitay-Gorod’)
Moscow 101000 Russia

phone: +7(495)772-95-90 *15026

email: city@hse.ru