The first step for this project was to figure out what I wanted to make. The guidelines for the project were you had to make a sign with letters that would hold itself together and be one piece. My first thought was Star Wars so I began drawing out the words and some lightsabers to hold the bottom together.
My next step was to put my idea on a digital platform so I began drawing it out in Adobe Illustrator. I quickly realized my first idea wouldn’t hold itself together so I kept looking for ideas on the internet. I found other, more basic, images of lightsabers and drew them in Illustrator, adding them to my design. This was what it looked like when I exported it into Fusion 360.
To cut through wood this thick we used a CNC, which uses a drill bit to cut the lines you tell it to. It uses multiple bits for different size pockets and is very easy to set up while using Fusion 360. this leads me to my next step Fusion.
Once the outline was in fusion 360 I extruded it .5 inches which was the height of the wood I was cutting, this allowed me to show how deep I needed to cut. I then made a second body which was the size of the wood I was cutting out of, 6.5" by 12.5", I then looked like the picture does where the bodies were layered and it was one piece with the design on the top.
Once it was placed in Fusion I had to make cut paths showing where the CNC machine had to cut. This was easy because of how Fusion works, I first selected the pockets I wanted cut then selected the bit I wanted to be used. This bit was found in the Dawson bit library which was updated for what the machine had. I used a 1/8 inches bit first clearing all material leaving .04 inches of wood next to the line then I used the same bit to go back and cut down to the line using a contour. I then cut the outside edge with a ¼ inch bit again leaving .04 wood on the outside later going back around with a ⅛ inch bit cutting down to the line. On the CNC you can only cut half of the length of the bit on each pass to not break the bit so it took a few passes to get through all the material.
Once I made my cut paths I put tape on the back of the wood I was using and the CNC table and glued them together. I then zeroed the CNC so it knew where the wood was on the table and in space then started the job. I started the job and as expected it cut the pockets and the outside, it used many passes and finished in about 30 minutes.
During this project, I found that designing in Adobe Illustrator and Fusion 360 made it easy to make my design a reality and quickly translate it to the CNC.
I also found that the size of the project was the hardest thing to work with, I had lots of little holes and pockets that the bits couldn’t fit in. Also using the CNC makes it so all inside corners aren’t sharp and are rounded.
If I was doing this again I would make the piece of wood I was working with bigger which would allow for the corners to look sharper and make the sign bigger.