This project has probably been most frustrating up to this point. Laser cutting seemed easy, but alas, I was proven wrong.
My first step was performing the kerf test listed in the homework instructions. Ana and I ultimately measured the kerf to be 0.004″, so this is what I went with as my kerf for my first cut.
Many things went wrong for my first cut. Firstly, in an effort to avoid burning the wood, I used the engraving and vector cut setting listed on the sheet next to the laser cutter for 1/4″ wood. I set my vector cut speed to 24%. This indeed did not burn the wood, but it also did not cut through the entire plank. In addition, the Epilog software would not recognize my engraved and vector cut elements, so I had to do 2 separate runs for each of them. This resulted in off-centered engraved figures.
The back of my first cut. It did not go through the wood.
The front of my first cut
Instead of starting over with a slower speed, I attempted to salvage this cut. I used the orbital sander to try and get through to the part that was cut, and then I used a razor to cut out the pieces. After a lot of work, I was able to assemble my box, but the described process ruined the aesthetic appearance of many of my fingers. In addition, I found it a little bit hard to assemble the box, and I think my measured kerf was just slightly off.
examples of the torn aesthetic appearance of the fingers.
I was not happy with the result, so I decided to try again. For my second try, I slowed the vector cut speed down to 15% and increased the kerf size to 0.005″. I also made every engraved image an .svg, which allowed for the Epilog software to engrave and vector cut in one run. I wanted to put masking tape over my wood to avoid burning it when it vector cut. However, this inhibited the laser from engraving my wood evenly, so I had to find another method.
My first try with masking tape did not engrave the wood evenly.
In an effort to avoid burning the wood, for the third try I: (1) engraved my wood, (2) placed masking tape over my wood, then (3) vector cut my wood. My cut pieces were finally cut through, there was minimal burning with this method, and my engraved images looked good.
A laser cut piece after I had engraved it without tape, placed tape over, and vector cut it.
The box looked much cleaner this time, and assembly was easy. I learned a lot through this experience, and I’m glad it’s over!
One side of my finished box. The finger edges are much darker than the first cut since I slowed down the speed.
Here is the cost breakdown:
Raw materials: 1/4″ 12×20 wood plank: $7.70 (includes scrap/waste)
Labor: Lab technician – $21/hour for 2 hours = $42
Machine Time: A Fusion Pro costs $619/month to lease. Given that there are 43,800 minutes in a month, and I used 11 minutes to cut my box, machine time would cost $0.15.
TOTAL: $49.85. Time would vary greatly depending on the speed of the project (and skill of the user).
