DIAMONDS OF THE GALAXY | ENGI 210: Prototyping and Fabrication

STEP 1: Diving into the SVG Code: Crafting the UFO Through Programming

Initial Pattern

Tweaking the SVG Code

Getting my hands dirty with the actual SVG code was pretty interesting! Instead of just relying on Adobe’s visual interface, I tweaked the code directly to get those UFO elements just right. Here’s what I played with:

Looking at my initial complex design, I realised I needed to take a step back and think about what would actually work best for water jet cutting. The original had all these intricate patterns and tight corners that, while cool in theory, might cause issues during cutting. So I went through a pretty thorough simplification process and edited my svg code to give me a simple design of UFO’s

With my adobe illustrator file tweaked, I was ready to start formatting and getting ready to print!

STEP 2: Preparing the Design for ProtoMAX: From SVG to Water Jet Layout

Layout Software

Moving my UFO design into the ProtoMAX software was like translating between two different languages. The interface you see here is way different from Adobe’s clean SVG workspace. First thing I noticed was the features I needed to change – this is crucial for getting the water jet cuts just right. I had to adjust several key parameters:

The layout conversion required some careful attention:

Part Side Gap: 0.05 inches (keeping it tight but safe)

Lead In/Lead Out Length: 0.05 inches (for clean entry/exit points)

Additionally, I edited the scale, thickness and autopath to ensure that my cutting process went smoothly

The trickiest part was making sure all my original SVG paths translated correctly into the ProtoMAX’s coordinate system. What looked perfect in Adobe sometimes needed tweaking here to ensure the water jet would follow the exact path we wanted. After fixing my layout, we were ready to cut.

PART 3: Learning from My First Water Jet Attempt and Reattempting

Failed Attempt

SETUP

Setting up the machine was pretty straightforward – clamped down my material with those red tabs you can see in the photo, made sure it was perfectly level on the cutting bed.

I made my first rookie mistake! I initially set up the cut with the wrong material thickness settings, which you can see in that first test piece. The water jet was cutting like it was working with thinner material, causing poor cut quality, especially around those delicate UFO beam patterns.

I had to pause, recalibrate, and adjust my material thickness settings from 0.001″ to the actual 0.69″ of my metal piece.

Success: Two UFOs Ready for Landing!

Post Cut Diamonds

After fixing those initial thickness settings, I finally got my two identical UFO designs cut perfectly! The water jet did an amazing job capturing all the details – from the precise diamond outline to those intricate beam patterns running through the middle.

POST PROCESSING: Sanding, Filling, and Painting

STEP 1: Sand Blasting

Man, sand blasting is where the real transformation begins! After getting those UFOs cut, they needed some serious surface work. I set up my sand blasting cabinet, got my safety gear on , and started blasting away. The coolest part was watching that rough, water jet-textured surface transform into this smooth, even finish.

STEP 2: Fine-Tuning with Filing

After the sand blast, I noticed some areas still needed that personal touch. I started with a coarser file to tackle any stubborn rough spots, especially around those water jet entry points. Then switched to progressively finer files to get that butter-smooth edge finish. The trickiest part was working around the UFO beam patterns – had to be super careful not to slip and scratch the surface we just sand blasted!

STEP 3: Bringing it Home with Spray Painting

This is where our UFOs really came to life! First things first – proper prep is everything. I wiped down both pieces with spirits to remove any filing dust or finger oils . Set up in a well-ventilated area, laid down some drop cloths, and started with a light black coat. The key was patience – multiple thin coats rather than one thick one. Between coats, I did light sanding with super fine grit to ensure that professional finish. After the final coat and clear protective layer, these UFOs looked ready to take off!

Cost Estimate

Material Costs: Aluminum Sheet (12in x 12in) – $14.99 from Home Depot Metal File – $8.99 from Home Depot Spray Paint – Silver – $6.99 from Home Depot Spray Paint – Clear Coat – $6.99 from Home Depot

Labor Costs: WaterJet Cutter Worker – $17.50/hr (1 hour) from Indeed.com Sand Blaster Worker – $18.25/hr (1 hour) from ZipRecruiter Prototyping Engineer – Custom Rate (Self)

Total Project Cost: $73.71

CONCLUSION

The experience gained in working with the water jet cutter and perfecting the post-processing techniques is invaluable for future projects. I enjoyed this project throroughly!

CLEAN WORKSPACE