Week 1 - Journal

This week's assignment was to prepare already existing design files and fabricate them using the laser cutter and the 3D printer.

Since I love toys and animals, I wanted to make a keychain and a puzzle. I searched for many models until I found an elephant keychain (https://www.thingiverse.com/thing:4013950/files) and an elephant jigsaw puzzle (https://3axis.co/laser-cut-wooden-elephants-jigsaw-puzzle-dxf-file/e1gklpvo/)

The softwares used for this assignment are Ultimaker Cura and RdWorks.

The machines used for this assignment are Malky ML1930 (laser cutter) and PRUSA i3 MK2 (3D printer).

The materials used for this assignment were plywood and PLA plastic (grey).

Slicing the STL file to prepare it for printing included several steps. First is to import the file in Ultimaker Cura, then to check the parameters and see if they need adjusting.

When I imported the file, it was too large that I had to scale it down to decrease its weight and time. Once I scaled it down, I adjusted the parameters as we were instructed in the intro session and then I sliced the keychain to see the final time and how many layers it would be. After slicing it and making sure everything is ready for printing, I exported the .gcode file to transfer it to the printer.

Preparing the DXF file for the laser cutter is an essential step before the fabrication. Using Rdworks, I imported the dxf file I downloaded then I scaled it to the size I want. After that, I changed the colour of the parts that I wanted to be engraved and the same for the ones I want to be cut. I saved the file in .rld format however, I did not change the speed and power as I still had to ask the fablab specialist about the specifics for the laser cutter there.

After arriving at the ODC fablab, I started opening my files and double-checking that everything is good to go. I started with the 3D printer as it would take a longer time to finish. I put the .gcode file on the sd card and started the printing process.

I then proceeded to the laser cutter and asked the fablab specialist about the parameters. After that, I adjusted my file accordingly, saved it (SaveToUfile), and put it on the flash drive. Then, I put the sheet of wood inside the laser cutting bed, adjusted the origin and the focus, followed the rest of the instructions, and started cutting.

I took feedback from Amr, a fellow student, who told me what could be improved about my model and how to avoid technical mistakes in the future. He also suggested the size and orientation of the laser cut model.

The pointers I took from Amr were about putting supports for things that are more than 90-degree angles in 3D printing to avoid any errors in my final printed model. He also told me how to change the origin of my pointer in Rdworks to match the origin of the laser cutting machine.

I faced two mishaps when fabricating my designs. The first was that the temperature of the 3D printer bed and nozzle was not stable due to the air conditioning in the lab. This resulted in the filament not melting enough and not sticking to the bed. The fablab specialist was not present so I had to consult with Omar who is an ex-maker and luckily was present at the time. He helped me understand why this was happening and told me to increase the temperature of both the nozzle and the bed to counteract the effect of the AC.

Another mishap that occurred during the laser cutting was that not all the engraving was done. Only the eyes of the elephants were done and the rest did not appear.

Knowing how to operate the machines on my own and trying it successfully will definitely help me with my final project. Understanding the parameters of each machine and becoming familiar with the softwares used will fasten the process of the final project. Along with learning about the machines and the softwares comes errors and mishaps which will help me avoid them in the future and build on the mistakes when proceeding in the final project.

Something that I will never forget from this week is seeing my design come to life (literally). Since I study product design in university, we were asked several times to 3D print our designs for prototypes. However, we used to give the .stl file to the specialist and then we receive our prototypes when they are done, I have never been involved in the fabrication process until this assignment where I got to witness everything first hand. It felt very gratifying to watch your design translate from a 3D model on your computer to a tangible object in your hand.