Randy Wallace_Assignment 2: Laser Cut Tote

Following the production of the hand machined totes, the class was tasked with a related assignment to modify our plans to spec for laser cut panels. The first step was to adjust the parameters to reflect the dimensions of the new material. We also needed to redefine the joining system to include box joints at the corners and mortis and tenons within the plane of some panels. 

Once all of the dimension call-outs and joining systems were completed, we defined the material and prepared, executed a drawing from the design, and export the drawing as a pdf or dxf file (I tried both processes). There was an instance in the Makerspace when the larger of the two laser cutters was off-line. Students were asked to resize their projects for thinner material and smaller art boards to fit the smaller of the two printers. I did this and had to correct some extrusions as I’d discovered some anomalies in the design. Long story short – I later reworked the drawing to the original scale (corrected to the calipered measurement against the stock material) as Ryan mentioned that the larger machine was working again. All of the efforts thus far were to plot the cut lines via vector lines.

Prior to working on the Zing laser cutter I incorporated some text and graphics onto the surface of some panels. These images would be etched into the surface via raster lines. I converted the image from color to black and white and created two text boxes. These graphics were then placed within the appropriate panels on the drawing in Illustrator. 

The drawings were then brought up on the desktop, printer parameters set, and the job was sent to the Zing printer. The material that I selected ended up being smaller than my drawing boards in the file; therefore, some of tenons and upper portion of the handle were not represented in the first attempt at cutting. Following the first board pass, Ryan suggested that we slow the cutting speed as the laser wasn’t cutting all of the way through the material. We did all of the vector cuts first, and then executed the raster cuts.

To assemble the tote, I had to separate the individual components from the mother board. Some components were troublesome as the cuts hadn’t completely separated the parts from the housing. I used a utility knife to complete the cuts.

Once the parts were separated, the glue up was fairly quick going. Ryan suggested using green tape to hold the joints together instead of clamps. I ended up only taping the corners while the glue cured for 24 hours.

Reflecting on the experience, I would improve several approaches when I take on a similar project. 1) I would measure my material prior to executing the cuts in the laser cutter to ensure that the drawing and material sizes synch; so that, I don’t need to recut and waste material. 2) When incorporating graphics for raster cuts, I’d lay create them on a transparent page. This would allow me to see the details such as joinery locations to allow for better placement.