2D Design & Computer Controlled Cutting
“I call our world Flatland, not because we call it so, but to make its nature clearer to you, my happy readers, who are privileged to live in Space.”
― Edwin Abbott Abbott, Flatland: A Romance of Many Dimensions
Modern 2D Computer Design & Cutting
In a Fab Lab or makerspace, the 2D cutting machines are typically 1) a laser, for cutting and etching many materials, and 2) a knife for cutting vinyl stickers on a backing. Designing for these platforms can happen in many forms and is an expanding field, but mainly this happens with vector software.
Related MakeHaven Badges for the unit:
Minimum: Laser Cutter, Vinyl Cutter
Extreme: Laser Cutter, Vinyl Cutter, Waterjet Cutter
For the course, we recommend that you get as many of the badges above as is practical. Also, it can be really helpful if you have earned them before the needed unit, so their acquisition does not eat in to your time to finish assignments. Coordinate with facilitators to complete badges.
Fab Academy:
These are in-depth discussions of topics related to this unit, borrowed with love from the Fab Academy archives. The videos linked here (and on the rest of the webpage) are intended to deepen your knowledge on the topics. They are not required for the Foundations of Fabrication course, but they are often good to watch for more perspectives on the same ideas. We love 🎧 listening to videos while doing the repetitive tasks of making; 👀peeking over whenever they've got something good on screen.
Fab Academy 2020: Computer Controlled Cutting (notes) Computer Controlled Cutting Review
Fab Academy 2019: Computer Controlled Cutting (notes) Computer Controlled Cutting Review
Fab Academy 2017: Computer Controlled Cutting (notes) Computer Controlled Cutting Review
Unit 7.1 =====
2D Design and Vinyl Cutter
Software for drawing in 2D, so that a machine can use the drawing to manufacture the designs --> vector drawing software
Inkscape [free, open source] (recommended)
Corel Draw [$$, one-time license]
Adobe Illustrator [$$$$, software subscription]
Software driver for MakeHaven vinyl cutter: ___________________
vector vs raster files (showing the internals of these files to make it concrete for learners)
vector files describe the shape's lines with XML code (usually .svg)
allows the lines to be scaled with a multiplier [like math class: f(x) ==> f(2x)]
files recognize the shapes & regions used in the image
since lines are specified, toolheads can be made to follow lines
raster files store color values for every pixel in hex numbers:
many many pixels make a picture
the file is ignorant to what shapes are present
does not stay smooth when zoomed in (pixels just cover more of screen)
stroke vs. fill for vector shapes
The stroke ‘hairline’ setting that exists in both Corel and Illustrator, but is absent from Inkscape [ solution: stroke width <0.02px ]
'kiss cutting' to cut through material, but not backing
layering stickers for multiple color effects in finalized sticker designs and positive space vs. negative space
Describe weeding and masking stickers
Multiple color sticker design processes
Document for past students: focused on Corel + Roland GS-24 (not MakeHaven pieces)
'kiss' cutting
Cut through vinyl, but not backing for retaining shape
weeding unwanted vinyl
Manually remove unwanted vinyl after the cut is finished
masking tape
Unstick vinyl from backing > maintain arrangement> place
registration marks
Marks on all layers, that are to align layers then removed
Single Piece Sticker
These are the simplest: just a sticker to put in place. Positive and negative space included.
Multiple Pieces (need masking)
When a sticker has separate parts, masking tape moves them into place together.
Multilayer (Coplanar)
Several separate stickers can make a more complex image. These are all on a single surface.
Multilayer (stacked)
Stacking stickers vertically adds complexity: be mindful of alignment and overlap.
Assignment [Unit 7.1] ---> Vector design and make on the vinyl cutter, laser or both (at a starting level)
Design & make 3 vinyl stickers that show you understand and can differentiate the skills needed for all kinds of stickers. This means you should make a sticker from each of these categories:
Single piece sticker
Multiple piece stickers (that need masking)
Multiple color sticker with or without registration marks
Coplanar colors
Stacked colors
Design & make a few laser cut objects that explore the basics of making with the laser engraving/ cutting processes. This will require a little exploration into how the designs relate to the laser processes:
raster cut something small: 1" x 1" (because this is slow)
vector cut something - generally 4" x 4" is a good place to start
vector etch the surface of a material (without cutting through)
use multiple settings within one cut job
Lecture
Unit 7.2 =====
Advanced 2D and Laser Cutting
Laser cutting basics:
Laser vector cutting vs. raster engraving
vector cuts have laser move along vector lines
hairline & < 0.02px
raster etching has the laser burn material away pixel-by-pixel, from grayscale version of the color in pixel (but there are other, exotic ways to map the burning as well)
laser kerf / press fit kits
focal length of the lens/ optics in machine
speed - power - frequency
vector cutting settings assigned by vector color
Digital Joinery - A set of documents used to teach these concepts to previous students. These documents cover 3D design and the process of building in 2.5D from a laser or CNC
Color Fill as a post-process & edge-lit acrylic for raster and vector cut pieces
Cut cardboard to measure the laser kerf (a series of slots). Make a press-fit thing of your own design! This press-fit thing can include any or all of the styles of Digital Joinery linked above.
Alternate: if you're already proficient with kerf + press-fit design, make some flexures 😄
Flexures in Delrin
"Flexures" are a fascinating section of making. All of the items shown in the video above are laser cut from delrin, or polyoxymethylene.
A longer video on 2D and 3D flexures in below.
Folding 2D-ish Materials
Increasingly, we are learning how to make things that fold. The video shown here highlights the utility of planning how things will fold or unfold within designed materials.
There is still lots to learn about the processes of designing for these actions, but it is an exciting and emerging field of study.
This topic presents an interesting boundary topic between 2D and 3D design that could be explored further.
This software from Tomohiro Tachi can help you turn any triangulated pattern into an origami fold pattern. We will come back to this when we discuss the STL files of 3D printing...
Extras!
There are some things that are fundamentally 2D that are worth mentioning, but don't quite belong here...