Inspirational picture of the design
The assignment of this week was to create a pen holder consists of 2 compartments that would hold two different stationary items & it was optional to made it 2.5D design only or to add 3D printed parts.
I decided to take this opportunity & create a unique pen holder including calendar & adjustable compartment size to suites different of user requirements.
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-Pen Holder Design
Step (1): I started by sketching the main compartment, so, I started by creating the two mirrored sides .
Step (2): T-slot were added with its right dimensions to the sketch to be used in connecting parts together.
Step (3): Then, I created the other two side.
Step (4): I Created the third side.
Step (5): I added circle with 3mm diameter to place printed captive nut to connect top & side together.
Step (6): creating the partition side that adjusts the compartment size depends on user needs.
Step (7): One of the main used tools is projection tool which used to project sketches & faces to other sketch to avoiding duplication of work, I used it here to project T-slots into the base which is going be used to allocate parts together.
Step (8): creating the base bottom & create slots to add T slot connections to connect all parts with the base.
Step (9): I extruded two sides, then I used the joint tool which used to assembly connect parts together to provide user with assurance that all parts fit each other perfectly.
Step (11): I jointed the 2 sides by selecting origin point on a side then picked the location of the point on the other side.
Step (11): I extruded all parts which extruded by 3mm thickness, which is the thickness of used plywood sheet.
Step (12): After that, I created a full assembly & attaching all parts together to have the final product.
II-Calender Design
Step (1): I started by sketching the three spinning circles.
Step (2): I added text on each one of them which refers to days number, days names & months.
Step (3): Then, I created the two sides that creates the back & front parts of the calender.
Step (4): I added openings on the front side to shows back circles that includes text.
Step (5): I created a projection for circles to create the spacer parts between calendar circles to provide smooth motion.
Step (6): I used projection tool to create the base bottom slots that would connect all parts with the base.
Step (7): I created the spacer part to creat a small frame.
Step (8): I projected spacer part & circles to add circular frame to hold a small photo.
Step (9): I extruded all parts by 3mm thickness, which is the thickness of used plywood sheet.
Step (10): After that, I created an assembly & attaching all parts together to have the final product.
Assembling is an amazing feature!!!
Printing & Cutting Preparations
Step (1): Then, I exported the captive nut bracket as STL file.
Step (2): Then, I uploaded the 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, the print time was 5 mins & consumed 1 grams of PLA.
Step (3): Then, I exported all parts to DXF files to prepare it for laser cutting machine, I used DXF for laser cutting plugin to export sketches from forms automatically.
Step (4): Then, I exported the DXF files & loaded all files to rhino to arrange them for laser cutting.
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 10 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 which is 215°C to start printing, the print took about 5 min to finish the design.
III-Assembling design
Then we can to the interesting part where designs became real on your hands, I assembled all parts together at their exact locations, then I used different M3 bolts to connect all parts & bolts had different lengths depends on the thickness of layers of wood than connected together.
The thing that I worried about while designing & fabrication was the fraction between wooden sheets while rotating the circles, that's why I created a clearance between sheets with 1mm to avoid high frictions & provide smooth motion & fortunately it works very well from first time.
I've learned this week about the different connection that can be used in laser cut wood to connect parts together, such as the fingered slots & T slots, also learned how to create your own 3D printed brackets that suits your design needs.
I guess the most interesting part was knowing more about plywood wood & the reason of neglecting its friction in some cases as it's a natural wood not like MDF wood that could have much more friction after using laser on it.