CNC Sign

Step 1(Choosing sign design): The first step was choosing an image or logo that I liked. I looked through a few options before deciding on something simpler—the Colorado Buffs logo.

Step 2(Making my design into a sketch and DXF file in Adobe Illustrator): I had to turn my logo into a sketch, which could be turned into a DXF and transferred to Fusion. My photo had transparency squares, making things tricky. In class, we learned to manage this by selecting everything (Command + A), using image trace, and reducing the colors to only the basics (the visible ones). For mine, I reduced it to four colors, selected and ungrouped everything, and then used Select > Fill Color to choose and delete the transparency squares color by color (grey and white). Finally, I outlined my logo’s shapes, created a sketch, saved it as a DXF, and transferred it to Fusion 360.

Step 3(Creating model on Fusion 360): Now that I have a DXF file, I open it in Fusion 360. Then, I created a plane under the bottom of the model; now I can create a sketch of the model. I then selected the areas of the sketch that I wanted to be deeper, pressed 'Extrude,' and set the distance to -0.5 inches to add depth to the model (which is currently flat). For any areas marked in red, I switched to Cut mode, selected the body, pressed Extrude, and chose Make Object. Then, I went to the Manufacture workspace to create tool paths. I created a setup, letting Fusion know the stock size and setting the X, Y, and Z axes. Under the Stock tab, I switched the setting to “From Solid” and selected Body 2 as the solid stock. Returning to setup, I specified the axis orientation by selecting the front-left-top corner as the box point. In the Model section, I told Fusion to select Body 1 and then turned off Body 2.

Step 4(Creating tool paths and emailing the NC program to the CNC machine): The next step after turning off my second body (so it doesn't get in the way) is to start creating my tool paths. First, I selected 2D Pocket as the first path and saved 2D Contour for last. Under Tools, I accessed Dawson FS tools and used Tool 6 (this tool depends on your project and its needs). In the third tab, I made the surface.

For 2D Contour, I skipped adjustments in the Heights tab, and then in the Passes tab, I disabled Stock to Leave and enabled Multiple Depths. Since this is the 2D Contour, I used Tool 8. Then, I selected the bottom edge in the Geometry tab, added a -0.02 offset in Bottom Heights, and confirmed the depth in Passes. Finally, I ran a simulation to make sure I got everything correct. Then I clicked my setup and clicked Create NC Program. I then verified that my project was named and was on 1001. After that, I saved the file to my computer and sent it to the maker space email.

Step 5(Retrieving wood piece, spray painting, and covering painted area with paint covering): I measured my piece previously in Fusion using the measure tool, and turned in my measurements to Mr. Supiro and he cut out a wood stock piece that matched my measurements. After retrieving my cutout, I spray painted it with white spray paint. So now that my wood stock was spray-painted white and fully dried, I covered it with a protective sheet. This would keep the white paint intact during carving and allow me to paint the carved areas black afterward without damaging the white finish.

(*Note about 2nd picture: It forgot to take a picture of my sign when it initially got cut so I have a picture of it cut but also with the final test pieces for my acrylic pieces)

Step 6(Cutting out my sign on the CNC): Now that I had my wooden stock prepped and my NC file sent to the CNC machine, I was now ready to cut it out. The cutting process starts by setting up my wood piece on the CNC. I tape the painted side up and tape the area on the table where I'm placing my piece as well. Then, I used super glue on the taped side of my wood piece and attached it to the taped area on the CNC. After making sure that my piece is attached, I then do the six preflight checks: tape and glue (make sure to check if the frame is REALLY glued onto the CNC table), make sure the air compressor is on, check that all the axes are in place (Z, Y, X) , and make sure my job is the one loaded. But we aren't ready to cut yet. First, we must move the machine to the area where my frame is glued. Then, I slowly lower it using the Z button, but I make sure not to lower it too much, maybe about 3 inches away. After the machine is set near the corner of my frame, I can turn on turtle mode and slowly lower the machine down to where I can start seeing a dark shadow made by the machine, but it still does not push down on my wood stock. I then had someone help me with the paper test to ensure it was close and accurate to my frame. Finally, I can move the machine back around the middle, let the CNC run my job, and remove my sign once it's finished cutting.

Step 7(Printing out my acrylic pieces): This was probably the hardest step for me; I struggled a lot to do what I intended. My original plan was to create an acrylic piece that I could fit inside my wooden sign-like inside the deep areas of it. However, because tool 6 was about a 1/4 inch cut, it made all my sharp edges and corners on my original design rounded-. Because I made my acrylic piece based on my original sketch from Fusion that had sharp edges still, it had sharp edges. But luckily, I learned how to round my edges using (check name) in Fusion. But this still wasn't enough. The edges and corners weren't round enough. So the next best choice was to just round the edges by 0.125 in. But this also wasn't round enough to fit inside my piece. So now I was stuck luckily Mr. Supiro helped me figure out a solution. The solution was to offset the outline in -0.2, and offset the horn in -0.5. I tested this solution one more time on a piece of wood to ensure I had gotten the correct measurements. And it worked, so I cut my outline out on my final piece of acrylic so I could slide them into my sign. I was finally done with all my base pieces now I just had to color and add final touches.

Step 8(Painting and final touches): Now that my acrylic pieces were finally finished, my sign was ready for paint and final touches. I first decided that I wanted the outline of my sign to be gold rather than white. So that's what I did; however, I did mess up in between and accidentally painted the horn gold, so I had to go back and fix that before class finished. My sign was now finished.

FINAL PRODUCT

Reflection Q's :

1. In your own words describe the major steps to successfully design something in illustrator, use it to model in fusion, and use laser cutter after cutting on the CNC.

The steps most important to going from AI to a CNC Sign are seen in my procedure. The first step is to find a logo from Google and then turn the design into a DXF that can be sent to Fusion 360. Now in Fusion, you can use extrude to create depth and make it an actual sign. Then, after adding depth and a solid around the model, you can start working on the 2D contour and 2D pocket. Once you're done with the 2D contour and 2D pocket, you can send the NC code to the CNC machine, where you can cut out your sign from your stock. Using the Epilogue engraver, you can create any acrylic or wood pieces you need.

2. What did you learn about the process of painting and masking?

By painting and then masking, you can apply different colors to the areas that you covered with the masking without messing up the paint you masked at all.

3. What part of CAD/CAM did you find most complicated or confusing?

The CAD was far easier than the CAM. The easiest part about the CAD was just creating the sketch around my model, but the harder part was adding depth to my 3D model. I messed up a few times with the depth going up or down because I didn't understand that having a negative extrude would make it go down into my piece, which is what I wanted. The CAM was way tougher than the CAM, though. The hardest part was creating the tool paths because there was so much to remember and input.

4. What lessons did you learn along the way about working through a multi step project?

I learned that taking notes about the steps you do and things you need to take note of is very important because multistep projects contain so many steps and instructions that it's hard to remember everything. So, taking note of everything is key. I also learned that

5. What tools/software did you learn to use in order to create your piece?

I learned how to offset lines in and out to make my outline smaller, which is helpful if you're trying to make something (like an acrylic or wood piece) fit inside another thing (like a sign). I also learned how to make a flat model gain depth by using the 'Extrude' tool in Fusion. Which was helpful when I was making different dimensions for my sign.

Planning doc: https://docs.google.com/document/d/1g794KImXgEiXSqJOKcWG_pV3qFvwgB8CsNWMwqL9Vgs/edit?tab=t.0

Materials:

Plywood

White Spray Paint

Black Spray Paint

Masking Tape

CNC Machine

Sand Paper/Sander

Black 1/8" Acrylic

Glue

Epilog Engraver

Gold Paint

Software:

Fusion 360

Adobe Illustrator

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