Week 2 - Journal

I should design eye glass to be applicable for daily use as an application on designing by using CAD software and digital fabrication via laser cut and 3d printer. 

My thoughts was

1- search to find real and authentic model

2- Using Fusion 360 to design both 2d and 3d parts. 

Software:

I practice on Fusion 360 through watching the uploaded videos and apply the separated project. 

Laser works.

Machines

3D printing: Prusa MK3

a-Sketching part: (For laser cut)

1- starting by drawing a rectangle from the original point with the proper dimensions for the eye frame 39*54 mm

2- Making offset by value (-3mm).

3- Felting the edges to adjust the frame.

4- Mirroring the whole sketch by drawing an axis from the original point.

5- select the lines needed for mirroring and select the axis of mirroring, then click ok.

6- moving one of the part to insert the mid section between lenses of the eye frame.

7- Making 2 holes with diameter 3mm to fix the arms later on.

d- Sketching part for 3d printing (2 arms):

1- starting by drawing a rectangle 5*100 mm from the original point.

2- Then trim one of its sides (the one opposite to the origin).

3- drawing a slot with 3 center points and link it with the trimmed part.

4- adjust the length of curved slot to 24 mm.

e- Extruding and Revolving the arms

1- After finishing the sketch.

2- Extrude it with value 3mm.

4- creating a new sketch at the end of the arm.

5- design a 3*3 square to revolve the body around it by angel 90 degree.

6- Making a hole in the revolved part 3.3 mm for the M3.

4- copy the arm as a new body.

5- Mirroring the copied arm.

6- Saving file as .stl

Implementation for laser:

1- Uploading the file on the machine.

2- Check the focus of the laser before starting.

3-press origin on the panel.

4- press frame to check the suitability outline of the plywood.

5- press pulse as a final confirmation before starting.

6- choosing the file and press start button.

Implementation for 3d printing:

1- Uploading G-Code file on the Sd card then connect it to the Prusa MK.

2- Choosing the file then press ok.

3- Monitoring the machine for a time to be sure that everything is ok without any errors.  

assembly process:

In this process I assembled the 2 final products laser cut and 3d printed parts by using 3MK. 

Fully defined challenge 

One of the great challenges while I designing the 2d sketch is forcing the whole sketch to be fully defined without FIX/UNFIX feature.

solution:-

I have tried many times with different methods but most of trials were ineffective and not satisfied until I discussed this issue with the instructor (Nada shagar) in the support session till I fixed the problem.

Nada noticed that every time after mirroring the sketch the mirrored part is undefined. she told me that "the axis of mirroring should be defined as well".

I did that and the whole sketch became fully defined. 

Laser cutting challenge:

During the cutting the Eye frame the plywood moved a way from the laser gun that causes unclear cut.

Reason: because I did not fix the wood by using the sticky tap.

Solution: I fixed the plywood and repeated the cutting again. 

3D printer challenge

During printing the arms the PLA cooled down quickly, and the first layer (Brim) suck to the Nosil.  

first Solution:

I pressed pause printing and repeated it again however, the problem appeared again.

second solution:

Fab lab specialist increases the temperature of the bed extra 5 degree and the problem solved directly. 

This week we applied one of the WoW project that inspired me for the final project.

Bookmark  fabrication:

We conducted mixed project or a combined one between laser cut and 3d printer.

Honestly, this project inspired me to use both 2d and 3d design in the same project for the best results.

One of the coolest thing this week is practicing more on 3d design on fusion.