After ENGI 120 and 200, I thought laser cutting would be a breeze, considering the obstacles I overcame to make the many iterations of our robot frame last year. As a result, I elected to approach this assignment in my own unique way, making a box that would fall into a beginner/proficient hybrid category.
To begin this assignment, I measured my kerf based on the instructions given in the assignment document. After cutting the pieces out, measuring the gap they left was not as easy as I thought it would be. The gap was extremely small and using the calipers to measure it yielded a different number each time. This inconsistency led me to just finding an average, 0.0095, which I would ultimately find to be incorrect.
After finding the kerf, I adjusted a template from Makercase to be the dimensions I desired. Instead of going for the cube based on the instructions, I decided upon a rectangular box with dividers. This template allowed me to incorporate the ‘assignment display’ aspect of the proficient level for this project. Based on the size of the sheet of wood we were given, I made my box 4x5x2. These dimensions assured that I would be able to cut at least two iterations on my box. After adjusting the tabs and kerf, I then downloaded the template and imported it into Adobe Illustrator.
Once in Adobe Illustrator, I added the required component to the box design, this included my name, the class, year, and the Sid Richardson crest. When I started this assignment, I knew that I would be giving the final product to my grandmother, so I added more designs that I thought would be appealing or meaningful to her. The sun, car, and house are representative of our relationship, while the flowers are just pretty. Then, I had to edit the properties of these shapes to ensure they were cut or engraved correctly. To properly vector the box pieces, I had to change the color and size of the lines, while also making sure everything was accurately grouped. To properly engrave(raster) the designs, I used Image Trace, setting the type to black and white, then ignored the color white. Then, it was time to cut.
I decided to use the new laser cutter as that is the one we used in the tutorial, and its operation was fresh in my mind. To double check the properties and operation of the laser cutter, I started by cutting out a small square with a T engraved in the center. With the success creation of this Scramble letter, I then proceed to set up the cut for my box. Most aspects of the document imported correctly and were already set to be either vectored or engraved. However, the Sid Richardson crest was showing as an entity to be vectorized. To fix this issue, I grouped the components of the crest and added them to a new selection set to be engraved. For the vectorized components, the settings were: speed of 50%, power of 35%, and frequency of 45% with cycles set to 4. For the engraved components the settings were: speed of 100%, power of 50%, and resolution of 600 DPI.
The cut went very smoothly, no flames and not issues. However, putting the box together proved more challenging. Every piece, except for the two side panels fit together seamless. Only two pieces not fitting was fairly confusing, especially since I was most worried about the divider pieces being messed up. Naturally, since it was the step, I struggled the most on, I blamed the kerf.
Changing the kerf required me to go through the entire process described above again, since I needed a brand-new template. The second time through, however, did not take as long as the first as I was able to do a lot of copying and pasting without having to change any properties.
My first attempt at this recut failed before the cutting even started. My wood panel was significantly more warped than before, causing the camera to display and even more inaccurate image. This inaccuracy caused me to place the template too close to the previously cut areas, leaving no room for the bottom row box panels. The second attempt went well, until the cutting. I am still not sure why, but after the second cycle of vectoring, the cut began to produce little flames. I turned down the power on the machine to makes sure I did not start a fire, but I had to go as low as 20% to stop the flames completely. This drastic change in the power setting, caused the wood to not be cut all the way through.
I tried to salvage the cut, as I had no more wood left to use, but using an Exacto knife to try to carve out each panel, proved fruitless. My only option was to use a mallet to force the side panels on from my first iteration. This approach mostly worked; however, the mallet caused a bit of chipping on the tabs.
Overall, I produced a box that fulfilled the requirements of the basic level, touched on the proficient level and will be a nice surprise for my grandma when I go home for fall break. While I hoped to have a perfect assembly, the use of the mallet did work and did not cause too drastic of chipping. I am happy with the box and believe that it is pretty cute!
Cost Breakdown: Raw Materials * Wood - (assuming a 24" x 24" sheet, $0.15 per square inch) $40.00 Labor * 4 hours x 5.00/hour = $20.00 Tools * Machinery owned by and housed in the OEDK Total: $60.00
