1. Design in Fusion 360

• Take standard Dimensions: from the internet to fit in

• 2D Sketching: I created a 2D sketch of the temples of the glasses in the plane of the front of the glasses.

  1. 90-angle part 

  2. start drawing the temple

  3. draw a rectangle 100x7.33 mm

  4. draw the two curves 

  5. then trim the unwanted parts

• extrude the part with a thickness of 2.8 mm

• fillet the end line in the curve of the temple with 1mm

• copy the part and paste the new one and joint both of them to the 90-angle part then combine them to make them one

• Appearance: Change it to plastic

4. Exporting to Cura

• File Export: The 3D mesh from Fusion 360 was exported as an STL file.

• Import to Cura: The STL file was imported into CURA.

• Slicing Settings: 3D Printing Settings in Cura

• Select your 3D printer which is PRUSA i3 MK2 3D printer

• material type PLA

1. Adjust Print Settings:

   • • Layer Height: 0.2mm

     • Infill Density: 20%

     • Extruder Temperature: 215°C

     • Bed Temperature: 60°C

2. Support and Adhesion:

   • Enable support is touching builplate 

   • Set bed adhesion 

3. Slice and Save: as a project which take 40 minutes and 5 grams

1. File Preparation:

• Check File: Ensure the design file is correctly set up and ready for printing and ensure the slicing time is correct and the machine is PRUSA i3 MK2.

• Upload File: Transfer the 3D design file onto an SD card using an SD reader connected to a flash drive due to the absence of an SD card slot on the laptop. (The G Code)

2. Machine Setup:

• Insert SD Card: Place the SD card into the 3D printer.

• Heat Up Machine: Preheat the printer to allow the filament material to be pulled up easily.

3. Printing Process:

• Select File: Choose the design file from the SD card menu.

• Start Print: Begin the printing process by pressing "OK".

• Initial Check: Observe the initial layers to ensure the process proceeds correctly.

4. Post-Printing:

• Remove Part: Once printing is finished, remove the magnetic bed from the machine and detach the printed part.

• Clean Bed: Clean the magnetic bed and return it to the printer.

• Remove Supports: Carefully remove the support structure from the design using a screwdriver.

• grit sanding the arc of the temples 

5. Finishing Touches:

• Documentation: Capture photos of each step for documentation purposes.

Machine Setup

1. File Preparation:

• Check File: Ensure the design file is correctly set up and ready for cutting.

• Speed and Power Settings: Verify each cutting mode's speed and power settings.

2. Machine Setup:

• Download File: Transfer the design file to the laser cutting machine.

• Set Origin: Position the laser at the starting point of the material.

• Frame Check: Check the frame to ensure the design fits within the material boundaries.

3. Cutting Process:

• Start Process: Initiate the laser cutting process.

• Monitor Process: Keep an eye on the cutting to ensure it proceeds smoothly and correctly.

Machine Setup

• Retrieve Design: Remove the finished design from the wood sheet.

• Sheet Handling: Take the remaining sheet material since it is personal property.

• Paint: Spray the cut design with black paint 

• Documentation: Take photos throughout the process for documentation purposes.

Problem:

During my assignment in Week One, where I was designing glasses, I encountered a challenge with the front part of the glasses. The front brake after assembly. This happened because I miscalculated the thickness of the material and the stress points where the temples were attached to the front frame. I also didn’t account for the kerf properly, leading to a weaker structure than intended.

Prevention:

This issue could have been prevented with a better procedure in the design phase. Ensuring that the thickness of the material is sufficient to withstand stress, especially at the joints, is crucial. A more thorough consideration of the kerf could have prevented breakage.

Solution:

The immediate solution I used was to reattach the broken part with glue. This provided a temporary fix, but it's not a durable or long-term solution. A better approach could involve redesigning the front part to include thicker material or reinforcement features, which would require extra time and effort that I didn't have during the assignment. 

Problem: 

Another problem occurred with the temples of the glasses, which deformed due to poor support during the 3D printing process. The design had thin sections that were prone to warping under the heat of the printing process because the support structure was inadequate.

Prevention:

This issue could have been avoided by carefully analyzing the 3D printing setup before starting the print. Ensuring that sufficient support structures are generated, especially in thin or overhanging areas, is critical. Additionally, selecting the right material with appropriate cooling settings could have minimized the warping.

Solution: 

By using abrasive tools to refine and achieve a better shape for the deformed temples. This solution worked to improve the overall appearance and functionality of the glasses. However, a more effective long-term solution might involve redesigning the temples for more uniform thickness or experimenting with different materials and printing orientations to minimize the risk of deformation.

Side note: Both come with trial and error with the tools and machine. 

انا عملت منقلة يا شلبي !