Embedded Files
Concepts
When we were first assigned the project, I wasn't too sure what I wanted to do so I started searching for different ideas. My first was a lantern, but it would have been too easy to create, my next idea was something like a design on a flat board, but we didn't have the time for me to do this as I would have to round the edges. I finally settled on a multi-layer Christmas design inspired by this pumpkin design that I saw. Once I settled on what I wanted to do, I started sketching out ideas.
Link to Planning Document: https://docs.google.com/document/d/1BL6YbWC2FofTuLWe-QXwBB-Rw-BFE4S7_aNNFfkOYJY/edit?tab=t.0
Illustrator
I created the majority of my illustrator design by myself, with the exception of the candy cane, which I image traced from an image I found online. I added the star by using the pre-existing model in Illustrator and created the different depths by copying and pasting the star again, just shrinking it. To combine with the candy cane, I used the shape builder tool to connect the spaces that would be at the same level. To create the lettered text in the middle, I put my text to go along an oval, and then I offset it to make what the letters would stand on top. Finally, for the berries, I combined 3 circles and using the shape builder, and for the leaves, I created my own design by adding together triangles and using the white arrow tool to shape in the shape I had sketched. After all of this I exported my design as a dxf to put into fusion.
Fusion: Design
I created a sketch, set my bottom plane, and imported my dxf Star into Fusion with a depth of 0.5 in. I now had my base model, but to create different details. For the highest layer, which would be white, I kept it at the same level which included the outside border, the second border that was slightly more in, the outside of the candy cane, and the berry and text support. The small area bordering around the outside of my star would be -0.15 inches deeper and the main middle of the star would be -0.25 inches from the top. I ran into some issues while at this stage, since the image trace that I used on the candy cane created extra lines that made it impossible to extrude, so I was forced to go back into Illustrator to find the lines and delete them. Lastly, I created the stock for the star by setting it slightly bigger than the star and extruding it to the same size, 0.5 inches. After all of this, I was ready to move onto the manufacture.
Fusion: Manufacture
Once I was finished with the design portion I moved onto the manufacturing part to create the tool paths for the inside of the star and for the outside. First I created my x, y, z point. First, go to set up, stock tab, change relative size to from solid and click on the stock to select. Select the stock, go back to set up and selective box point and select the bottom left corner of your stock. Then go to model, selection box, then click body one. Next to create the 2d pocket (the inside indents) click 2d pocket, under tool hit select, Dawson fs tools #6 (1/4 inch bit). That selects the tool you want to use to cut. Then go to the third tab, geometry, and select the bottom surface (inside piglet). Then go to paces, turn off stock to leave, turn on multiple depths, and verify that maximum routing is correct (half of the diameter of the bit). Next up for the 2d contour, under tool select Dawson fs tool 8 (1/2 inch bit), then go to geometry then select the outside bottom edge. go to heights and go to bottom heights and offset by -0.02, passes and select multiply depth and maximum rounding double. Lastly, I created a copy of my 2d pocket, changed the tool to 1/8th bit, and turned on resting machine which went back and cut all of the smaller areas that the larger 1/4th inch bit couldn't. After that, the tool paths were created and I spray-painted my wood white and layered the blue masking tape on top so I could spray paint again once cut.
CNC Machine
Once I was done with everything in Fusion, I created my NC program and sent it to the makerspace email to run my job. I used green tape to cover the entire backside of my wood and taped on the CNC machine to cover the same amount as my wood covers and super glued the two tapes together so my wood wouldn't stick to the CNC machine. Once I made sure my would was sturdy, I loaded my job and set up x, and y points, and then my z point using the paper method. Once that was all done, I checked my 6 steps, x, y, and, z were all set, my job was loaded, the fan was on, and my wood was glued and sturdy. I started my job and vacuumed the wood scraps as it was cutting so make sure that the blue mask would stay on. Once my job finished I sanded all of the sides and insides.
Epilog Laser
For the Epilog Laser, I needed to cut 5 things out of acrylic, the white and red candy cane stripes, the letters in the center, the leaves, and the berries. I trial-ran the white and red candy cane strips multiple times using wood so that the shapes would fit as best as possible. Because the CNC can only round edges with the tools we use, I had to curve all of the edges of the parts and I needed to slightly shrink them so that they could fit using the offset tool. For the rest of them, I did not need to do this as they were not fitting into any shape, but rather sitting on top of the wood. For all of the parts, I set the stroke to -0.001. I used white acrylic, sparkly green acrylic, and sparkly red acrylic. I also needed to engrave a design that I created in Illustrator I aligned my design to where I placed my star by using the camera on the laser cutter. For all of these, I printed the design and made sure that I imported the correct material that the machine was cutting.
Finishing Touches
After cutting on the CNC, spray-painting, and cutting out and engraving everything on the laser cutter, I put on clear coat and super glued everything together to create the final star.
Reflection Questions:
I was asked about the process to create my acrylic, so it allowed me to explain the whole process behind it, including the process of creating the illustrator file, off-setting, sending it to the epilog, etc. It was nice to fully explain my full process instead of just hearing that the cut out was nice.
The hardest thing to explain was the whole process of making the Fusion file. I felt that if I tried to explain the whole thing, then it would just get too convoluted for people to understand, so I felt like I had to simplify it a lot. I could have done a better job of mixing simplicity while still explaining the process thoroughly.
I was able to accomplish everything I set out to do in this project, although some areas might have been rushed, I was able to finish everything i hoped to successfully. I especially like the colors I chose in the end, as I didn't have any colors set up from the beginning. I also think the berries and pattern turned out well since I had to make them myself and was a bit nervous about that aspect of the star.
I didn't encounter too many issues when in the creation of my piece, but I did meet a lot of time challenges. I ended up having to create the pattern design at home and was rushing to finish at the end so that I would finish at home (although I didn't need to be 100% done by the showcase). In fusion I ended up with a lot of issues in Fusion because when I image traced the candy cane, it created multiple different versions that when brought into fusion, just messed my whole thing up which resulted in a lot of back and forth between illustrator and fusion to fix my model.
If I were to redo this project, I would have made it a bit bigger because I felt that it didn't feel as different from my other ones, and if it was bigger, I could have added more details in the pattern design. I also would have made the pattern larger or more cluttered since it left a lot of empty space that I didn't like. I did this originally because I was nervous that the laser cutter wouldn't be too accurate, but it didn't leave any burnt marks and it was easy to set up so I didn't need to shrink the design. Overall however, I'm pretty pleased with how this turned out.
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