Week 2 -

"A-BEE-SEE"

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)

The assignment this week was to design a pair of glasses consists of 3 parts:

the front face: it should be designed in fusion 360 using sketches and extrude command only then exported as a dxf file and laser cut it.
The 2 side Arms: designed on fusion as well but using at least one of these commands(loft, revolve, fillet or chamfer) and exported it as stl file to be printed.
then all part should be connected together using 3M bolts and nuts.

My design concept was taken from bees i found them interesting insects and i like hexagons so i designed the glasses frame hexagonal shaped and in my opinion it worked perfectly it wasn't that extra and i think it matches my personality the center part is also a hexagon with some oval shapes and i speed cut and engraved them to look like bee strips and the hands my first idea was to make them shaped like a bee hive in the first 15-20mm with a honey drop to make the rest of the hand but i simplified it a lot at the end to be just a functional hand.

Tool Chain

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

Laser Cutting

3D Printing

laserwork v6 software

for preparing the files it accept alot of formats but we mostly use dxf or ai, power and speed is modified then the file is exported as rld file.

laser cutter mostly used with sheet shaped materials like acrylic, wood, paper and even fabrics.

in fab lab we will use plywood, mdf and acrylic and for this project i used plywood(3mm).

El Malky ML149 CO2 Laser Cutter.

Technical Specs

Working area: 140 x 90 cm
Laser tube: 130 WATT
Engraving Speed: Up to 600 mm/sec
Cutting Speed: Up to 400 mm/sec
Minimum Engraving size: English letter 1mm * 1mm

ultimaker cura 5.2.1

for preparing files for printing it accept stl files it allow changing parameters as layer height, speed, bed and nozzle temperature ,then export the file as a gcode

pla+ filament

PRUSA i3 MK2 3D Printer

Technical Specs

Build volume: 250mm wide, 210mm deep and 200 mm tall
Layer height: 0.05 – 0.35 mm
Nozzle Diameter: 0.4mm
Max hotend/heatbed temp.: 300 °C / 110 °C.

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 step was it get the standard dimensions for glasses

second i made a quick sketch of my idea

then i started to design it on fusion

design phase

i started with the glasses with an inscribed polygon with 6 sides and radius 28mm then the center part is an inscribed polygon of radius 10mm and the two polygons have a collineared side then offset the bigger polygons inside 3mm and fillet all the sides and mirror it to make the second glass.

then for the bolt holes draw a circle with diameter 3mm, 28mm above the ground and the side of the polygon is tangent to it then draw an inscribed polygon(6 sides) with the same center of the circle and one of its sides is collinear to a side of the inner polygon of the glass, then exported it as a dxf file.

the hand is consists of 3 parts first i draw the side sketch as shown and extruded it 2 mm and then filleted all external edges then i made the part with the bolt hole i first made 2 circles 1 with 3.3 diameter and the second 5.5 diameter to represent the nut inner and outer dimensions then i made a hexagon to be the same shape made in the wooden part put cuted its last 2 sides extruded it for 2mm but i didn't like the connection between the two bodies so i cut the straight part of the first body, projected its end and then loft the two sketched together and here is the hand, mirror all 3 parts and then export it as stl to be prepared to 3d printer.

Preparation phase

I imported the dxf file to laserwork v6 move the sketch near the origin and select the type of cut done to each line(each color is connected to a layer and will be processed with the parameters selected to this layer) then modified the speed and the power depending on the cut or engrave i want, make sure the speed cut and engraving will be done before cutting and then export the file one more time as rld

I imported the stl file to cura software edited the parameters to layer height 0.2, infill 20%, material pla, printing temperature 215 and bed temperature 60,support overhang angle 50,build plate adhesive type brim and then sliced it, it would take 39min and 5 grams after checking everything now we export it as a gcode file.

Media2.mp4

hand.mp4

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?

WhatsApp Video 2023-02-05 at 17.38.03.mp4

laser cutting glasses frame:

make sure all the parameters is right and the file format is rld.
put the plywood sheet and fix it with tape.
open the machine and relocate the origin and check the focus.
download the rld file to the machine and frame it to ensure its dimensions and orientation are right and it fits in the sheet.
close the lid and start the file.

WhatsApp Video 2023-02-05 at 17.37.47.mp4

3d printing the hands:

make sure all the parameters are right and the file format is gcode.
make sure the bed is clean.
if you want to change the filament color, preheat the nozzle, unload filament, select the color needed, cut the filament end to make it sharp (nearly 45 degrees), and load the filament.
send the file to the card insert it slowly and wait until the machine reads it
choose the file and start it.
watch the first 2 layers to make sure everything is ok.

then connecting all parts together using m3 bolts and nuts

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)

1st when exporting the laser cut file as dxf there was a problem as the body was extruded from 2 different sketches so when exported there was 2 dxf files so i searched and there was a tutorial and its way was to create a new sketch and then project all the parts on it and voila, there is our final sketch, and actually that was good as it deleted the intersecting lines by its own, exported it and it's done.

2nd when editing the file on laserworks v6 when changing the colour of the lines it all appeared black i didn't know the problem but when cutting the machine engraved and speed cut the parts then it cut them and here is the problem the lined was duplicated that's why it appeared all black so we deleted the overlapping lines and re-cut it and another problem was solved.

3rd when i printed the hands the printing was isolated from the bed we cleaned the bed and start it again but it happened again so "moaz" said that maybe because of the temperature so we increased the bed temperature to 70 and slowed down the speed a little bit and finally all is good

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.

Happy planter with a small edit (eyelashes)

making a fully defined sketch with a 3 points arc slot was so annoying as it need more than any other figure, we need at least 2 dim for 2 points and a radius, too much steps for one shape so i wanted to try it more than others and that's way i made the lashes in the first place but i think it turned out cute.

Assignment Design Files

frame.f3d

frame .dxf

frame.rld

hands.f3d

hands.stl

hands.3mf

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