In week 2, a cool pair of glasses were shown as an example, it was made of wooden front with the word "GUCCI" cut on it and plastic frame arms.
So, I thought it might be cool if I do something similar but with FAB LAB written above the frame instead using a standard found online.
(https://www.glassesgallery.com/size-guide)
Malky design laser cutting machine
3-mm Ply wood
Fusion 360
RDworks for cutting preparations
Prusa I3 MK3S 3D-printer
PLA
M3 bolts&nuts
Ultimaker Cura for model slicing
Designing was kind of fun since it can be done through many ways in fusion 360.
Steps are as follow:
A hexagon was drawn in the center and a dimension of 37 mm (standard) was set as shown.
An offset of 3mm was made then the whole shape was copied 17mm far beside it.
For the glasses bridge a conic curve was used with a rho of 0.5 and the inflection point was dimensioned for each curve to be almost in the middle and as thick as possible.
Then two rectangles for the arms connections and also the hole circles were drawn and dimensioned.
Having the shape of the glasses fully definded, the separating lines inside the shape were trimmed.
Using the text tool, "FAB LAB" was added and positioned along the upper line as a path.
The final shape was then extruded (and this is important for some problems to avoid).
You can add an appearance if you want as well.
The arm middle line was drawn and dimension according to standard.
A fillet was added with a radius of 22.5mm.
Here comes a tricky but essential step, Planes, the first plane is the front plane (standard one), then an angled plane with 45 degrees inclination was made and offset to 2 position along the arm middle line and a 1 normal front plane offset was made.
On the front plane, the start geometry of the arm was drawn according the dimensions set before in the glasses front frame.
In the second plane (near the end of the straight line before the fillet), the end geometry of the arm was also drawn as shown.
In the third plane (inclined plane after the fillet), geometry was altered to be smooth as possible, so, a circle was drawn.
In the last one, a smaller circle was drawn keeping in mind that the center of all those geometries are made Coincident with arm middle line.
Using the loft feature, the four geometries were connected, and the first profile was edited in the setting of the loft to be directional and set manually to have a proper shape.
A proper fillet was added to the end of the arm.
Using the front plane again, both connection extended parts of the arm weredrawn and dimensioned as shown.
Using sweep feature, the sketch as profile and the edge as the path, the connection was extruded (the proper value was 0.016 and produced almost 2mm thickness).
Saved the file as STL, then modified sweep sketch to get the second arm and exported the second arm STL file.
For DXF file preparation:
the file was imported in RDworks.
lines were set as cutting lines. (speed:40,power:45)
made sure the dimensions and position are as wanted.
then was saved and exported also as .ai just in case the machine's PC has an older version of RDworks.
The file was imported into the PC's software as .ai.
Made sure the cutting speed and power are as wanted then downloaded the file into the machine.
Set the origin point 2.5 mm from the edge of the wooden sheet and started cutting.
Then the part was sprayed.
To print the arms :
The STL files were dropped in Cura.
Rotated the parts to have minimum supports.
Set the Infill to be 30%.
Set the resolution to be normal (0.15mm) to get a proper time period (34 mins).
Made sure that the temperature is set to be 215 C degrees.
The dimensions of the arms were very difficult to deal with since the arm's end was 1mm in diameter (which was smaller than the supports).
The connection broke while removing the supports and had to do another print.
The second one had weird skirt and I shouldn't have ignored it since that caused errors along the way and the connections weren't even printed.
Finally, in the third try, with help from instructor (& fabrication specialist) Eman , the arms were printed perfectly but still looked weird.
Final output
As mentioned in the preparation section, there is a problem that happen if we decide to convert our sketch into DXF, which is that the Text is separated by default in the dxf file so if we were to cut the file as it is, the letters will be cut and separated from the frame.
One solution for this is "project" feature in fusion, using the extruded face, then, using the sketch projected as a source for the DXF file.
Also, The "Skirt" in the 3d printings are VERY important, Do NOT ignore them and whenever the dimensions are small, you should consider removing supprts, since removing them after printing WILL be a pain.
to avoid weird arms, next time, just use sweep 🥲. And Never print a 1mm.
Applying the concept of mixed design in the final project would really help, allowing different techniques to be used together to assemble the final project, also, the efficient usage of all the materials available to us instead of depending mainly on one resource or material.
Dimensions in Files that will be printed in tolerances, For example, these glasses' arm holes need to be suitable for M3 bolts (which are almost 3mm in diameter), but when dimesioned were set to have a diameter of 3.3 mm.
The printer heats the filament to be able to soften and extrude it through the nozzle but then the filament cools down and the dimensions shrink a little, Therefore, Such tolerances should be considered before printing.
One of the Hands-on activities was to make a mixed design bookmark.
Our Design wasn't really soppused to come out like that but it still came out to be a unique bookmark with a head that looks like Groot from Marvel.