Week #2 - Journal

Papar mobile holder + pen holder

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)

for this week's assignment, I searched for a laser cut mobile holder on google. And as a cartoon lover, the elephant took my heart, so I inspired the design from the beautiful cartoon " بابار فيل "

Tool Chain

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

software: Fusion 360 for designing
RDWorks for preparing the file for laser cutting

machine: EL MALKY ML1930 laser cutter

materials: 3mm Plywood used in ODC
3mm nuts and bolts to join the parts together

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?

First, some hand sketches to define main dimensions.

Then, using Fusion 360
I first sketched on side plane a construction rectangle with dimensions of 100x180 mm
1. I sketched the side first: I started from the right bottom at the leg and fixed the first point
2. Using line from create I sketched the legs
3. Then to sketch elephant's trunk I used 3 points arc to make different arcs
4. I made sure everything was fully defined by giving dimensions to all arcs and define the x and y dimension of the center of arc to a defined point or line
5. After finishing the side I made fillets at each corner to make it smooth not sharp edged.
" I then made slots randomly on the side but defined it then measured the distance between them to define the dimensions of the bottom and front & back parts before sketching them."

6. Then the bottom and the front & back: Also by making a construction rectangle first which I defined after finishing the slots in the side part, I sketched half or quarter of it using lines then used mirror to complete my sketch.
7. I also sketched the T-slots for 3 mm nuts and bolts using this drawing file: T-slot dimensions

8. Next step was to extrude all parts to 3 mm and make each part as a separate component. Then make a copy of the side part and the front to make the back part.

9. After extrusion, I assembled all parts together using rigid joints by selecting assembly the choose a line in the slot in first component then select the other line I want to join with in the tab of the second component.

10. At last, I changed the appearance to make it look nice

11. Finally, I exported each sketch as dxf from sketches at the left.

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?

Dimensions

Using RDWorks I imported all the sketches and arranged it in the sheet then checked the dimensions.

Power & Speed

it was all needed to cut so I set all lines power of cut to 60 " but check overcoming challenges for update ;) " and speed to 10.

Preview

I saw the preview and the estimated time for fabrication.

*To start laser cutting I moved the .rd file to the machine.
*put my 50x30mm, 3mm Plywood sheet.
set the origin point.
*tracked the frame of the design.

WhatsApp Video 2022-08-09 at 11.00.22 AM.mp4

*after running the laser cutter started to cut the wood and it took 4mins 22secs.

WhatsApp Video 2022-08-09 at 11.00.45 AM.mp4

After cutting it's assembly time ^_^ I placed the front, back and the bottom on one side first one at a time using slots as my guide.

when I finished these sides I placed the other side of Papar on them.

to assemble parts together I used 3mm nuts and bolts.

First, place the nut in it's place in the T-slot then place your bolt from the hole to fit in the nut then tighten it using screw driver.

Overcoming Challenges

What kinds of challenges or problems did you face while doing the assignment, tutorials, or exercises? How did you solve them? Did you ask for help from an instructor or peer? Please provide a link to the tutorial or article that you used to solve your problem (if any)

The problem was that when I Imported the dxf sketches in RDworks it showed with construction lines attached to main lines so when I tried to remove it, it removed main lines too.
when I tried to remove construction lines in Fusion the sketch became not fully defined.

The solution was that I select all the sketch then click on select nodes and select all nodes
I choose break nodes so all the lines break apart
It's now time to select the lines I don't want and delete it

The other problem was that the laser burnt the wood.

So I asked the person who used the laser cutter after me to reduce the power to 50 and it worked very well and didn't burn.

Final Project

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

Now, I could use T-slots and tabs in my design to make it easier if I needed at any point to open the device to fix something.

It also helped me to imagine the joints.

WOW!

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

Drawing the rocking chair and fabricating it was cool. Could we make it in bigger scale ! ^_^

Assignment Design Files

bottom-one part.dxf

front & back- 2 parts.dxf

side-2 parts.dxf

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