Laser Cutting the Box

I used the Fusion Pro 48 Laser Cutter, imported my design to Corel Draw and made sure that my vector cut was on hairline stroke. To see if my design worked I first printed it on cardboard, and then I would print the final copy on wood. Followed the work flow for the Fusion Pro 48 Laser Cutter.

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I cut the design on cardboard just like how I cut my butterfly design and followed the workflow of how to use the laser and cutter, and then chose the type of cardboard. I used 1/8 inch cardboard, which would fit the size of my acrylic.

Once the cardboard was cut, I taped the pieces together to see how my box would look, and check for alterations. I realized that the slit for my acrylic was too wide, and that a hole is also needed to utilize my potentiometer, and to provide access for wiring.

Using my original box plans, I utilized Inkscape and adjusted the depth of my slit, I added a hole for my potentiometer, and a square-shaped box so the port of my Arduino would fit. I used a caliper to measure the dimensions of the acrylic, potentiometer, and Arduino port.

Followed the same steps to cut the first cardboard box, and then taped the box to see how it looks. Everything worked, so I printed it on wood.

I went to the Fusion Pro 48 Laser Cutter and first imported my design to Corel Draw. Made sure that my vector cut was on hairline stroke and printed the box on 1/8 inch wood.

I taped the box and placed all components to check if they fit. The Arduino port wouldn't fit, so instead of wasting materials, I decided to sand the hole down so the Arduino port would fit.

After spending a hour of sanding, the Arduino port fit into the slot. If I could redo this step, I would edit the dimensions on Corel Draw, and then send it to the laser cutter again.

Fusion Pro 48 Laser Cutter Work Flow

Importing Files from corelDRAW to Epilog Dashboard, and preparing for the printer-

Open your .CDR file in corelDRAW on the pc connected to the FusionPro
Print your file using Ctrl + P
Select Epilog Engraver under the Printer options
Select “Use printer default (Custom, Landscape)” under the Page options
Check your Preferences by going on to

-Preferences…

-Advanced…

-Paper Size has to pe “PostScript Custom Page Size”

-Then Click ok until your back to the Print page

Click on the Color tab at the top of the Print page
Set the Color to RGB
Click on the PostScript tab at the top of the Print page
Make sure that “Convert True Type to Type 1” is NOT checked
Click Apply on the bottom of the Print page
Click Print on the bottom of the Print page, this will pull up the Epilog Dashboard with your file
Before doing anything else, properly align the Two integrated FusionPro cameras by selecting on the machines Touch Interface (see Icons on the FusionPro Touch Interface) NOTE: The camera video feed will not appear accurately if the machine is not focused for the material on the bed. This is a critical step for EVERY single print job.

-Jog

-Then Jog the machines lens to somewhere on your material

-Click the Auto Focus button and wait until the FusionPro is done

-Then Click the Park Axis Button

If your design isn't centered/positioned how you want it to be, Click on your design and drag and drop in into the correct position (you will have video feed coming in from the FusionPro to help with design placement)
Alternatively, while you have your design selected, you can use the blue bar on the left of the window to position your design using X & Y values in correspondence to a point on the workplane
Here you can also rotate and scale your design to fit your needs
Go to the Right side of the window
As long as you have jogged and focused using the machine’s touchscreen, you can turn off Auto Focus in the Epilog Dashboard menu.

Setting up your Material settings -

Select your Material and Put in into the FusionPro

On the Right side of the window under the Auto Focus tab, you have your Processes
Make sure your Processes view is set to combined, unless planning on just Vectoring or just Engraving
Click on the Process you intend on cutting
Under Process Type, Select Engrave or Vector depending on which you intend that process to be (the Off Process Type can be used in that specific process does not need to be sent to the printer, this is just like clicking “don’t print” in corel)
Next, Click the file folder with the down arrow next to the Process name, to Import the Material Settings
Find the Right Material and Resolution, Click it, and It will be used on that Process
Alternatively, you can Color Map your design by clicking on the process you want to Color Map, and then selecting Color under the Split By setting
Then Repeat all steps under the “Setting up your Material settings” for any remaining Processes

Sending Prints to Job Manager and the FusionPro-

At the very top of the Epilog Dashboard, you can select how the FusionPro is connected
If the FusionPro is plugged into the PC via a USB cord, you can select USB Connection
If Not, or if having problems with wired connection, select Web Connection under the same drop down
Under that bar you have the ability to change the file name before you send it to the laser, if wanted
When your File is Prepared, and your Material settings are correct, click “Send to JM” and then “Print” in the bottom left hand corner, this will send the File from Dashboard to Job Manager, save your settings in Job Manager, and then to the FusionPro

Starting your Cut on the FusionPro-

If you are ever in doubt of where the FusionPro is going to cut your design, click the Trace icon on the Touch Interface and the laser will trace an outline of the area of the work surface
Check to Make sure that all Blower switches are on before proceeding
Check to make sure that your material is aligned correctly
On the Touch Interface, click on the job menu, and then select your Print (the most recent file is always at the top) the file chosen will be highlighted in blue
Then click the Play button to the left of the joystick to start your print
The FusionPro will show all of your settings set on the Touch Interface, as well as a ETA while printing

The Final Box

I wood-glued the tabs of the box together and Voila!!

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Vinyl Sticker

Acrylic Cutting

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