2016

Fablab CEPT
Faculty of Design CEPT University

Rudrapalsinh Solanki

                                                    Week-3

Computer-controlled cutting

Assignment

 

1. Cut something on the vinyl cutter.

2. Design, make, and document a parametric press-fit construction kit.

Vinyl Cutting:

 

Vinyl cutting was the most simplest work that I learned in the minimum time. The vinyl cutting is a type of computer controlled machine where it works in one axis and cuts the material with a specific force defined and the speed. The small Roland vinyl cutter look like computer printer. The computer can control the movement of a sharp blade which cuts the vinyl/ the material used for cutting. This blade is used to cut out shapes and letters from sheets of thin self-adhesive plastic (vinyl).

 

I downloaded Cut studio  and started working on it. The first thing that I worked on the vinyl cutter is to load the material and check the zero of the machine or the origin of the sheet.

 

 

 

Once the Roland  CutStudio is installed I switched to Vinyl cutter and started working on the machine.

 

Step one is to load the vinyl sheet to the maachine. I selected blue vinyl paper to the machine.

Once the vinyl paper is loaded in the machine I made origin set in the machine and the test cutline was checked.

Once origin of the Roland cutter is set so now test was to make a square in a circle. So I removed the vinyl from the main sheet and checked if the cutting was properly done or not.

I am now ready for making a design in cut studio. I selected a geometry jpg file from the Internet to cut from the vinyl cutter.

STEP_01 The Cut Studio window was very simple and very easy to work with.

STEP_02 The image is drag and dropped in the cut studio window.

STEP_03 Once the image is dropped the jpg is converted to the line drawing for cutting.

STEP_04 The file then is accepted as a vector file.

STEP_05 The file then is aseparated and now we can delete it and keep vector file.

STEP_06 The vector file is ready for cutting in vinyl cutter.

STEP_07 The scale of the vector file is reduced to 50 mm to 60 mm

STEP_08 The final file then is plotted and the victor file is sent to the vinyl cutter.

STEP_09 Last step is to set the paper and cut it using blue vinyl paper

STEP_10 Once the Cutting is started for the file and it took only 2 minutes for cutting. REMEMBER TO RESET THE ORIGIN OF THE MACHINE AFTER TEST CUTTING.

STEP_11 After the cutting is done I removed the vinyl first layer and placed it on another surface.

Once the first layer is place I removed second layer. As all the smaller squares were not useful I removed all of those and finally removed the third layer and placed it on another surface.

STEP_12 After all the cutting and removing the vinyl I have  stuck it to the white base object .

Press Fit Construction:

 

Press fit construction is the my most favorite exercise in all the assignments. As a design student I always keep on exploring on the parametric design strategies and its construction techniques.

 

Press fit construction gave me idea to design a joint/module that can keep on adding/growing in nature. The intention of the exercise is to develop a module that can grow in x/y/z (multiple) directions.

 

I started working on a hexagonal geometry as it has a possibility to inter-lock with each other in a closed packing form(It can fix into each other without leaving any negative space).

 

The assignment was started in Rhinoceros software.

 

Rhinoceros is a software that is used for processes of computer-aided design (CAD), computer-aided manufacturing (CAM), rapid prototyping and also used in many other industries.

 

Rhino helps me to work easily on my idea and to develop on to my working method.

 

First idea for working on a module came from the honey comb structure which is a hexagonal closed packing structure. The first draft of the module was similar to honey comb.

 

We have Epilog mini 12*24 laser cutter. For further details refer to the LINK.

 

The specifications of the laser cutter is :

 

Power: 40 W

Bed size  Area: 24*12

Laser source: air-cooled CO2 laser tubes

Maximum material thickness that can be processed : 8mm

Intelligent Memory Capacity: 64 MB

Electrical Requirements: Auto-switching power supply accommodates 110 to 240 volts, 50 or 60 Hz, single phase, 15 amp AC

Print Interface: 10 Base-T Ethernet or USB Connection. Compatible with Windows® XP/Vista/7/8.

Resolution: User controlled from 75 to 1200 dpi

Functionality :

1. Paper cutting from 1mm to 8mm

2. Making of the sheet to depth of 3/5mm with the 80% efficiency.

3. Many materials can be used in the laser cutting machine. Soft and hard materials are easy to work with till 6 mm thickness .

4. It can cut the material wood/MFD/Paper easily till 5 mm of thickness

5. It can work as a engraving and etching machine and It really works well for engraving and etching on any surface.

STEP_01

 

The hexagonal module led me to re-think on the parameters that I wanted to define before making/deriving the module. The hexagon gave the reference for the module.

 

I started developing the module from the hexagon taking its internal divisions into consideration.

STEP_02

 

The hexagonal shape is slowly transformed into the equilateral triangles and equally divided into segments. A circle is drawn using the edges/vertices's of the hexagon

STEP_03

 

The shape is changed to the six sided figure which looks like a flower but it is not exactly a flower but it has similar geometry like flower. The figure will help me get the final form of the module from the hexagon shape.

STEP_04

 

The circle evolves into the module that is what I was looking for the press fit. This was the initial module that helped me further  to develop for the better module that works as desired module.

STEP_05

 

The module derived has the possibility to grow in all the direction. The hexagonal module can be interlocked in all the 3 axis. The working of the module is tested through rhino 3D modeling.

STEP_06

STEP_07

 

 

Once all the module are finalized the module are arranged in the closed pack cutting pattern for the final cutting of the pattern.

STEP_08

 

 

Once the cutting patterns are ready it is taken to print/ laser cutting.

The file is set for the cutting of the pattern on the laser cutting machine. The 2.5 mm MDF sheet selected for making the module.

Remember to switch on the machine before printing the file

 

 

The file is set for the cutting of the board. The setting of the laser cutter is set and ready to cut the board. Now  place the MDF sheet of  2.65 mm thickness

 

 

GO These is the most important button to start the laser cutting once the file is loaded.

STOP Can stop the machine at any point if there is any need.

RESET It resets the position of the laser cutter.

Wait till the yellow light stops blinking. The yellow light denotes that the data is now uploaded in the laser machine.

 

The machine keeps the data till it is not switched off.

Once there is any error you can directly press stop and press RESET for the  home of laser head.

The focus of the bed automatically from the software of either we can do that while the machine is under work.

STEP_09

STEP_10

Once the file is cut from the laser cutter, the individual modules are connected to each other.

 

LOGIC and UNDERSTANDING THE PLAY BETWEEN THE PARTS

 

 

THE CUT OF THE PIECE SHOULD BE OF THE SAME SIZE OF THE MATERIAL AND THE SIZE OF THE CUT

IN THE NEXT PIECE I TRIED TO CHANGE THE FORM DECREASE THE SIZE FROM THE TOP

DIFFERENT EDGE CONDITIONS FOR LOCKING THE PIECE  TO EACH OTHER

PLAY BETWEEN THE PIECES CAN BE SEEN IN THE IMAGES SHOWN BELOW

After all the cutting of the different modules I finalized 2 different geometry module. One with the triangle having the press fit access to the corner of the module. The first module gave possibility to develop in all the axis with 16 modules foeming one sphere which looks like a square.

Module 01: Basic intersection  through 3 sides - 2 sides and then 1 side in base

Module 02: Formation of a sphere through triangular intersection

Module 03: The growth of the geometry in all the direction of the basic cube.

This another module that is finalize as it has possibility to grow  in all the axis. Its growth ranges from + x/y/z axis to -x/y/z. The module is based on a hexagonal form and the length is doubled the size of the edge.

Module 04: Dual axis interlocking of the module and forming a triangular base pyramid

Module 05: This ia another interlocking of the same module in +/- x axis and the n forming a sphere in the  + z  direction.

Week 03 Files