The idea for the assignment is to design cool glasses with a mixed design, featuring a wood-fabricated frame and 3D-printed side arms. I was inspired by Harry Potter glasses because my sister is one of the people obsessed with that series. I started by trying to think of how to make it cool or more creative. Then I decided to add the Deathly Hallows symbol, which represent the three magical objects: The Elder Wand, the Resurrection Stone, and the Cloak of Invisibility.
I used fusion 360 application to sketch the design of the glasses frame, and save the design as .dxf.
I used LaserWork V6 Application in order to prepare the .dxf prepared on fusion and save it to RLD. file.
Plywood 3mm is the material used in my design on laser cutting machine.
This Laser cutter Machine used to emit a laser that can cut and engrave according to the settled power and speed.
I used Fusion 360 application to sketch the design of the glasses arms and save the design as .stl.
I used UltiMaker Cura Application in order to prepare my. stl file for printing and save it as .gcode.
PLA filament is an affordable material that can be used in 3D printers to print the desired model.
Prusa i3 MK2 printer can read g.code file and print the 3D model.
I started by drawing 2 circles from the origin with diameters 47mm and 55 mm, then i decided to draw between these 2-circles the Deathly Hallows symbol.
I faced a problem to draw and define the triangle with a circle inside it and a line both of them, so i decided to make every shape separately.
After drawing and defining each shape, i started making a circular pattern, and i repeated 12 times to be like a clock when looking at it.
Then i started measuring the distance of the bridge(17mm), drawing a line in the middle in order to help me acting like the axis of symmetry when making Mirror.
Then, i started to draw the bridge using three point arc slot between the 2-glasses.
I decided to make the hole of M3 Screw inside the frame itself so i edited the two circles in the middle to be (3.2mm), and these 2mm are tolerance for the kerf error made by the machine.
I made offset to the outer glasses frame and the inner circles of the lens by (0.5mm) just to create outer line that will be cut and the inner line to be speed cut.
Then i extruded the glasses 3mm to visualize its final result, and also in order to help me remove the useless constraints that i need to trim but i cannot.
Finally, i made a project on the sketch itself to projectile the outline needed and neglect the non needed ones.
Save as .dxf, open LaserWorks and import the file.
After finishing the previous design, i challenged myself to try what i couldn't do, which is to define the triangle with a circle inside it and a line both of them.
I started by drawing 2 circles from the origin with diameters 47mm and 55 mm, then i decided to draw between these 2-circles the Deathly Hallows symbol.
After many trials i did it and they are defined.
I started making a circular pattern, and i repeated 12 times to be like a clock when looking at it.
Then i started measuring the distance of the bridge(17mm), drawing a line in the middle in order to help me acting like the axis of symmetry when making Mirror.
Then, i started to draw the bridge using three point arc slot between the 2-glasses.
I faced a lot of problems trying to extrude this design, but after many trials its finally extruded(3mm).
I added a new sketch on the face of the glasses, in order to write a text on the bridge (Hogwarts).
I made a project on the sketch to select the needed outlines for laser cutting and neglect the rest.
Finally i saved the sketch as dxf.
When i went to LaserWorks to prepare the file for cutting, the surprise was that not all the triangles wanted to be selected, i tried to gest back to Fusion and edit a lot to overcome this issue but I didn't know where is the issue, so Unfortunately i went back to the previous design.
I imported my dxl file on LaserWorks and set the speed and power:
Black: Cut ( speed 40 and Power 45)
Blue: Speed cut (speed 250, Power 15)
Red: Engraving (Scan)(speed 250, Power 30)
Save the file as .rld.
I started by sketching the arm of the glasses on the perpendicular plane of the frame.
The dimension of my arm will be 140mm.
I started by drawing a construction line with 140mm length to be a reference.
I drew a line with length 92mm and another line parallel to it with length 90 mm and distance between them 4mm.
From the end of each of the pervious lines, i started to make another shorted lines with angle, taking into consideration the reference line.
I drew a line connecting the previous 2-lines together.
I drew a small rectangle (4*2mm) in order to be the short part for the screw.
I start extruding the short part of screw by 2mm on the its perpendicular plane. then i drew a circle on it and extrude cut the circle to make the hole.
Then, I extruded the main arm and make Fillet to its sides in order to make it more smooth, then i used Mirror tool to create the other side.
I combined the body parts of each arm in one body and save each arm as .stl to prepare it on cura.
Open cura, import the .stl file.
Set the infill to 20%, the resolution 0.15, temperature 215.
In my design it didn't require support, but i turned on the Adhesion to make sure it will be accurate.
Turn on the machine from the green circular button.
Open Laser work from the PC connected to the machine , and open my .rld file.
Make sure that the power and speed of cut and scan are adjusted.
Make sure that the origin of software is correctly set with the machine.
Press download, so that the file will be downloaded to the machine.
Now, from the machine, press on File button., and select my file.
Put my plywood sheet in the desired place, where the nozzel is pointing to the sheet, make sure its fixed.
Move the nozzel to the desired place on the wood, the press origin to set it as the origin that i wanted.
Adjust the focus.
Press on frame button to see the area of cutting and make sure that its okay.
Close the door, and press start.
Set the infill to 20%, the resolution 0.2, temperature 215.
In my design it didn't require support or adhesion.
Make sure that the .gcode file is saved on the SD card.
Insert the SD card into the printer.
Press on the control knob and choose preheat, then press unload filament in order to change the filament color.
Put the desired filament, press on load filament.
Make sure that the bed is clean.
Press print from SD, then select my file name.
The machine will start.
First:
Actually, this is not the first inspirational design, at the beginning i wanted to make a flower glasses as shown in the picture, but it was really hard to define the petals of the flower and after even defining and make mirror. the mirrored side wasn't defined, so i gave up and went to the current design.
Second:
As it clear in the preparation part i had 2 trials to reach the current design, as at first i wanted to make the circle to be inside the triangle and every thing was defined and okay until i went to LaserWork and see that the tangent between the triangle sides and circle sometimes cut the triangle with make it impossible to be selected in LaserWork, i went back to fusion and tried different diameters of the circle until the circle wasn't tangent at all but also that didn't work!!!
Third:
I faced problem with the bridge as when i want to trim the inner parts to make sure that it will not be cut by the laser machine that also was impossible until i asked for my instructor help, and she helped me to use project tool which helped me to solve this problem.
Fourth:
I aslo faced problem with the 3D arms, as i struggled how to extrude the L-shape until, i reached how to extrude each part alone along different axis.
Fifth:
When i printed one of my 3D arms, the L part was to weak and it got broken after inserting the nail inside it, So the fab lab specialist asked me to extrude it with more thickness to overcome this challenge and the problem was solved.
Sixth:
After cutting my glasses on the laser cutting machine it falls on the ground and got broken from the middle because of the 2-letters on the bridge that i gave them the cutting feature, so i recut it again and make the 2-letter Scan.
Finally, it was really a hard week for me with alot of challenges but i really learned alot and did things i never expect i can do it.
It was really a huge knowledge and skills to design and create the project from A to Z, these skills and knowledge will help me to design and create my own idea of the Final Project InshaAllah.
Working on a mixed design model of a Robot bookmark (Head and Body) using Fusion 360 with this great team was truly amazing. 😁😍
I always prefer working in a team and enjoy the vibes even when we are stressed to finish it within a specific time. It was an enjoyable session. 😊