For this assignment, I went with the beginner-level assignment.
Step 1: Editing the Adobe File
For my diamond, I planned on adding the first letter of my name onto the diamond using Adobe Illustrator. As shown below, I picked a font that was symmetrical like the diamond which looked visually appealing to me.
Step 2: Protomax LAYOUT/MAKE
To convert the adobe illustrator file into a readable format for the waterjet cutter I ran it through Protomax Layout and make. In Protomax layout I cleaned the file, defined the dimensions, and ran their automated jet pathing. Shown below is the file after running it through Layout.
In Protomax Make, I zeroed the water jet nozzle over the part of the steel metal sheet where there was space to cut as shown below. That is also where I inserted the thickness (0.2 in) and type of material I was using.
Before starting the cut, I had to adjust the nozzle height using the metal piece attached to the water jet. The nozzle had to be a thickness length of the metal piece away from the metal sheet. After doing so, I started the cut through Protomax MAKE. Shown below are the cut-out pieces.
Step 3: Post-Process
It was very apparent right after the cut that the edges of the diamonds were rough. To smooth out the edges I used a rasp on the outside and inside edges.
Next was sanding the surfaces. This smoothed and cleaned the surface by removing any distinct scratches and blemishes. First I sanded them thoroughly with the 220 grit then 400 grit and finished them off with 800 then 2000 grit sandpaper.
Finally, to give the pieces a clean look I spray-painted them blue. I would’ve used red since that was my favorite color, but I couldn’t find any (blue is my 2nd favorite color). However, after spraying it I found some red acrylic paint and painted over the dried blue spray paint. With a paintbrush, the paint formed with ridges so it looked blue with red stripes. I liked this look a lot so I kept it that way with the final result shown below.
Total Cost:
Material Cost: (7.25 in^2 of steel sheet metal) * (0.04$/in^2 of sheet metal) + (1 oz of blue spray paint) * (1.06 $/oz of blue spray paint) + (1 oz of red acrylic paint) * (0.45$/oz of red acrylic paint) = $1.8
Labor Time: (15 min for Step 1) + (45 min for Step 2) + (3 hours for Step 3) = 4 hours
Total Labor Cost: (4 hours) x (11$/hr*) = $44
Total Overall Cost = $1.8 + $44 = $45.80
*Based off Lab Assistant Salary
