The Process
This week, I set out to use the laser cutter for the first time. We were tasked with creating a 4x4x4″ laser cut box with finger joints. Using the 2D plans from MakerCase, I begin with measuring the thickness of the wooden boards we were provided. Using a digital caliper, my sheet measured 0.185″ in thickness, an important factor to note and input into the MakerCase software. Before I could complete my box plans, I also had to determine the kerf of the machine and my vector cut settings. I did this by laser cutting a kerf box, pictured below.
After removing the individual pieces and pushing the inner columns up to one another, I measured the gap with a caliper, divided the measurement by 10, and input the kerf for the 2D drawing.
After downloading the resulting file, I transferred my work over to Adobe Illustrator (AI). Here, I planned on adding text, the GSA crest, and some cute doodle art to give my box more personality. Below is my final design.
After ensuring my engraving lines were set to a stroke of 0.003″, and my vector (cutting) lines to 0.001″, I imported my file into the Epilog template in AI in the computer connected to the laser cutter. I positioned the upper left corner of my piece to the top left corner of the artboard, with the coordinates of x:0.5″ and y: 0.5″.
I turned on the Epilog Laser Cutting Machine, turned the vent on, positioned my sheet on wood on the cutting bed, and focused the laser tip before finalizing my settings in AI.
I wanted a soft caramel color for my engravings, therefore I selected the following raster settings: 70% speed, 30% power, and 10 frequency. For the vector cutting settings, I selected 4s speed, 100% power, and 10 frequency, in accordance with the OEDK recommendations for cutting 1/4″ thick wood. I set the process to begin, and watched the beauty unfold.
I watched the pieces fall through one by one, signaling to me that my vector cutting was deep enough. After pulling the pieces out, I was so happy how they turned out – minimal laser burn. Some char got on my fingers after handling the edges, so I put on gloves to assemble the box so prevent the faces from getting dirty. The finger joints fit perfectly, requiring moderate force to push the edges into place. I lightly sanded the entirety of the box with a 220-grit sandpaper piece. After assembling all the sides of the laser cut box, I couldn’t help but smile. I think I may be joining #TeamLaserCutting with Dr. W.
Before leaving, I ensured the laser cutter was powered off, along with the exhaust. I tidied up my workstation to make sure I left it just as I had found it – clean.
Reflection
I believe this process went more smoothly for me because I was trained on the laser cutting machine less than 24 hours before I was able to cut my box. Having determined my design and prepped them prior to my session expedite this process. For future attempts, I would love to spend even more time designing my pieces, however, I learned with my box (boasting very cute, detailed, and intricate lines), the cutting and engraving process may take some time. I saw that my piece was going to take a while (22min) so I arrived at the OEDK early Friday to avoid using the machine when other students may need it. I am so happy with the outcome, but some things I will look to improve on in subsequent projects:
- Use gloves when handling cut pieces, though sandpaper did help to clean off some of the imperfections.
- Challenge myself with design, perhaps trying a photoengraving next time.
- Try other joints/living components
Cost Estimate
Materials
- 1/4″ x 2′ x 4′ plywood: $14.95 (Home Depot)
- 1 pc 220-grit sandpaper: $1.03 (MSC)
Time/Labor
- 3 hours at $15/hour: $45
Overhead
- Estimated Facility Costs: $30 (15/hour x 2 hours)
- Waste and scrap: $5 (estimate)
Total: $95.98
As I gain experience, the quality may increase, and production costs will drop as the time required to make it shortens. This saved time will likely come from less need to troubleshoot and better familiarity with AI.
