Inspirational picture of the design
The assignment of this week was to create unconventional unique glasses, also it was required to make it a mixed design of 2.5D & 3D parts.
I decided to create sun & moon glasses which was inspired by the emojis 🌑☀️ so, the right lens would refer to the moon & left one would refer to the sun.
I- Laser cutting (Frame):
Software:
Fusion 360 (to design & export DXF file).
Rhino (to convert nurbs to polygons).
Laserwork (to send design to machine).
Material:
Plywood sheet with thickness 3mm.
M3 bolts with different length & nuts.
Machine:
Laser cutting machine.
II- 3D Printing (Temple):
Software:
Fusion 360 (to design & export STL file).
Ultimater Cura (to create gcode file for the machine).
Material:
PLA filament with gray color.
M3 bolts with different length & nuts.
Machine:
Prusia MK3 printer.
Softwares & machines used
I-Frame Design
Step (1): I started by searching for glasses lens & bridge width & temple length standard dimensions to able to design the glasses frame according to accurate dimensions.
Step (2): Next step was to sketch the frame, I started by creating main outlines of the frame.
Step (3): Then I created fillet for top of bridge & trimmed unneeded lines to make it one connected object.
Step (4): I sketched extra designing lines to the right lens using spline & I used fixed constrains to define splines.
Step (5): Then, I did the same thing on the left lens & used fixed constrains to define its splines & I had to add extra dimensions for lines that lost its defining while triming.
Step (6): I added two circles with 3m diameter for M3 bolts which is going to be used to connect frame & temple together after fabrication.
Step (7): I extruded the sketch by 3mm thickness, which is the thickness of used plywood sheet, I did that just to check design appearance at its final stage.
Step (8): I changed the frame appearance to get a close similar look for how it would look like after fabrication.
Step (9): After that, I exported the sketch as DXF file.
Step (10): I uploaded the exported DXF file to Laserwork & sat the parameters to be speed 30m/s & 65% power.
II-Temple Design
Step (1): I started by sketching temple.
Step (2): Next step was to add circles with 3m diameter for M3 bolts which is going to be used to connect frame & temple together after fabrication.
Step (3): I extruded the sketch by 3mm thickness, which is the thickness of used plywood sheet.
Step (4): I created an offset plane to mirror the model to have another mirrored copy of it .
Step (4): I created a copy of the temple by mirroring it to create a pair of glasses temples with then, I filleted their corners by 5mm radius to .
Step (3): I changed the frame appearance to get a close similar look for how it would look like after fabrication.
Step (7): After that, I exported the pair of the temples' mesh with as STL files.
Step (3): I uploaded the exported STL file to Cure to slice it with 0.3 mm layer height, 3 permitter walls & 10% infill density, also sat temperature to 215°C & exported gcode file & loaded it to printer using SD card, the print time was 30 mins & consumed 8 grams of PLA.
I-Laser Cutting
Using the laser cutter machine, I opened the .rld file, then named the file & downloaded it to the machine.
After that I sat the origin point of cutting & tracked the design space frame, then I started the cutting process which took about 30 min to finish the design.
II-3D Printing
Using 3D printer, I loaded the .gcode file that has been sliced by Cura from the SD card, then I selected the file from the printer & start printing process, it takes a while to reach the required temperature to print PLA to start printing, the print took about 30min to finish the design.
III-Assembling design
To connect frame & temples together, I used M3 bolts to connect them, I made two bolts for each temple to avoid rotation around it's axis.
Something boring I encountered through creating designs was that using fixed constraints doesn't made it a flexible thing that affected by other changes which made me in every editing in design I had to break constraints to be able to make adjustments, and that's why drawing by using splines isn't a recommended thing, that why I suggest using arcs instead of splines to easily define the sketches.
As the main aim of this assignment was to be able to create unique designs using Fusion 360 for 2.5D & 3D designs, which will definitely be part of the final project as it's going to be mixed product including both fabrications.
Thing that I've experimented & it was very interesting to learn was to print with gap, I know it wasn't part of the assignment or even diploma's scope, but it was such an interesting thing to try & actually it works perfectly & I created hinge that moves around itself with only one single time print using gap technique, I guess 3D printing had many & many things to learn & try to make :")
3D printed movable hinge