Week 1 - Journal

Ideation

Tell us about your assignment's idea for this week. Why do you care about this idea? What inspired you? (Please include images or links to sources of inspiration)

Well, in the first week There are some mainly activities which are including taking the first step into getting ideation for a model of bladeless fan, sketching and making low fidelity prototype with cardboard model intended to simulate the life cycle of the final medium fidelity project.

Next, getting familiar with machines like Laser Cutter and 3D Printer by preparing design models and working on them using those machines and software such as LaswerWorks and the Ultimaker Cura software was for the 3d printing operation.

Laser Cutter Machine

Bladeless Fan

Prusa i3 Machine for 3D Printing

Tool Chain

Which software/machines/materials did you use in the assignment? Why?

To make progress on the Laser Cutter machine it was recommended to prepare a DXF file design with 2D in first, either from websites or by myself. I decided to pick it up from 3axis.co website.

Next, I have to upload the DXF design file to the LaserWorks software to adjust the required orientations and other parameters such as power and speed that will be performed on the machine to be able to estimate the required time and material cost. I should not have missed that the cutting gadget (machine head) starts from the original point on the selected material sheet to avoid wasting material "the green point in the top left corner in the screenshot".

After that I need to convert the updated DXF design file to G-Code so that I could download it to the Laser Cutter machine to recognize it and choose a 50cm x 30cm sheet of plywood to be worked on.

Wall Clock model on the LaserWorks Software

Wall Clock be worked on a plywood sheet by the Laser Cutter machine

Ultimaker Cura is the software I used to set up a STL design file that "we can also design it ourselves or choose from websites such as Thingiverse as I did".

Next, as I did in the LaserWorks software, I have to set the required dimensions and whether there is any supports needed to estimate the grams consumed and the time that will be spent in the 3D printer. (In my case with the butterfly cover, I didn't need to put in any supports in that position as it normalize the cost of time and grams consumed)

Therefore, I converted the final design to G-code and uploaded to the Prusa i3 machine to print the 3D butterfly cover.

I should note that when working on a 3D Printer machine which is the Prusa i3 in our case, I have to let the machine (Nozzle) configure the dimensions of the bed to be worked on so that it does not print in a place outside the specified area.

Also, Let us DO NOT forget setting the Filament to Generic PLA means that Nozzle temperature will be 210°C and if was not that I need to check it.

Butterfly cover on the Ultimaker Cura Software

Prusa i3 machine.mp4

Butterfly cover on the Prusa i3 machine

Design/Preparation Process

Explain the design and/or preparation process of your assignment. How did you use the tool or software to design and/or prepare your assignment before fabrication/implementation?

In Laser Cutting Operation, first I had to have a DXF design file in 2D but how can I get it? … There were two options, either do it myself or pick it up from websites such as 3 aixs.co as I did. Next, I must upload it to LaserWorks Software so that I can adjust the required dimensions and set other parameters such as power and speed so I can estimate the time consumed and the cost of quality too. Let us DO NOT forget that I must check the mode of the model whether it is cut or scan or both selection!

This goes back to the type of the model we're working on, but in my case, I choose only cut mode for the entire wall clock.

Hence, I saved the changes and downloaded the final design file to the laser cutter machine with the file renamed as “Clock”.

While working on 3D Printing, I had to have a STL design file with 3D in first, there are also two options, either do it myself or select it from websites such as Thingiverse as I did.

Next, I must upload it to Ultimaker Cura Software so that I can set the required dimensions and check other parameters such as:

Adjust the print settings to 0.2 mm. "It is ideal for obtaining good quality detail at a reasonable time cost"
Set Infill to be 20%. It is not recommended to be 100% due to the potential problems generated, knowing that the higher the percentage the higher the cost in grams and time spent. "Not recommended anyway with too high percentage"
Set the filament to Generic PLA with Nozzle temperature 210°C “I must check this before starting”
Adjust custom settings such as Brim to make the model better for the print bed by printing a little extra material around the bottom of the model.
Adjust the supports if needed to make the printed model at good quality (in my case, thanks to my Fab Lab specialist, I was able to print the butterfly cover without any supports with the position reversed).

Finally, I sliced the model to estimate the cost of time and grams involved, then I converted the final design file to G-code with a new name as following: “Prusa4_Butterfly_9g_54min_PLA_0.2Q” and downloaded it to the Prusa i3 Printer by SD Card.

Decorative Wall Clock on LaserWorks software

Development/Implementation Process

Explain the development/implementation process of your assignment. How did you use the machine/tool to manufacture or implement the design of your assignment?

To operate the model of decorative wall clock on the Laser Cutter machine after downloading the final design to the machine and renaming it, as we can see in the next video, to reach that level of implementation, I had first to use the arrow keys to move the cutting gadget (machine head) to the top left corner of the machine, then put in a good sheet of plywood material of 500 mm x 300 mm, check the machine focus by pressing the Pulse button for less than a second, pressing Origin to set the effective cutting area and making sure the design fits perfectly, then I moved the machine like it’s cutting a rectangular piece of wood that can contain my design size but without emitting a laser. Next step I pressed file and selected the design file I named and finally I clicked RUN and closed the laser cutter lid door due to safety rules.

laser work_journal.mp4

Wall Clock work done by Laser Cutting Machine

And for the 3d printing, I have encourage to make a butterfly cover for a voronoi lamp as it shown in the following photo and wish I could make the outside shell also but it was a bit tricky.

For printing the model of Butterfly Cover in 3D on the Prusa i3 printer, I used the control knob to do the last needed steps on the machine to start printing the model.

Prusa i3_ journal.mp4

Butterfly Cover 3d printed by Prusa i3 Machine

3D Printed Butterfly Cover

The butterfly cover is at a little small scale but I guess it will be okay for other purposes too!

Community of Learning

Did you ask for feedback? What are the ideas that others have contributed or suggested? What was someone else’s idea that you built upon? How did you help your peers? How did your peers help you?

Title of Media

Dream Catcher model .Gcode on Ultimaker Cura software

Yes, I wanted to print out the Dream Catcher model but due to the minimum orientations and there are more details would require more supports and higher dimensions, which means time cost and grams which I don't have. So, my Fab Lap specialist advised me to choose another simple model and I was lucky to have a Plan B which is the butterfly Cover that I printed.

Also, I wanted to create a Roman Numerals Gear Clock on a Laser Cutter Machine using LaserWorks software, but because I picked up the model as cdr design file from the website, although I converted the format to DXF format, I missed more details when I uploaded it to LaserWorks software and it wasn't the only experience, frankly, so I realized it was a waste of time and effort. So, I decided not to use cdr format files again and only DXF would be the right decision for my LaserWorks software.

Roman Numerals Gear Clock Model on LaserWorks software

Overcoming Challenges

When you got stuck, what/who did you turn to? At what point did you have to pause to research or learn more before moving on? What are some mistakes, pitfalls, or challenges that others can avoid if they were doing this assignment?

In the case of 3D Printing, I had the challenge of changing the filament color, so I asked the help of a Fab Lab specialist with that, and to be honest I can't be sure enough up to that moment of documentation that I can properly cut/prepare its wire of the filament spool, but I guess i can be sure enough next time!

In the case of Laser Cutting, I've had a challenge getting some functions to work with the machine, but that may indicate that it's my first time, so I'll do my best next time.

If anyone else did the same assignment, I would first recommend him to do nothing without the Fab Lab Specialist's confirmation at least in the first time and should make sure that he takes care of the required safety rules for his own safety and the Lab safety too!

Final Project

How can you use the skills and knowledge that you've acquired this week in your final project?

Well, that is a good question actually!

I think learning how to work on machines like Laser Cutter and 3D Printer will be more helpful in doing the designs and handwork required for the final project designs especially when there is not enough time to ask for help so start doing it myself in the first week this will bring me to a useful skill in Emergency times perhaps!

WOW!

What is the coolest thing that you've learned this week? What is something that you will never forget from this week?

Doing it myself!

I guess that was the coolest one I learned in the first week and I am so excited for what is more coming next weeks!

Back to What I will never forget, may I say the friendly environment that makes progress and helps create more passion and willingness to do our best and the strength to encourage ourselves not to be afraid of mistakes but to enjoy what we do and simply take it. Things don't have to be done from the first trial!

Weekly Digest [OPTIONAL]

Tell us about any other cool things that you've made this week: in the Hands-on activity, tutorial examples, exercises, or any other cool mini-project that you tried out aside from the assignment.