2nd. Week

Goal

Designcool glasses for personal usage creating laser cut front part and 3D printed parts for handels .

The reference

Tool Chain

For this week we had to use a new software to present our ideas as 2.5 D and 3 D models .

For this Task I used Fusion 360 to present my Idea . I started to draw the front part and the handles in separated files .

Saved the front file as a DXF file and the handles as STL files

Then I inserted the DXF file to laserworks to prepare the file to be cut by laser cutting machine .

Inserted the STL file to Cura to prepare handles to be 3D printed

I used the laser cutting machine to fabricate glasses frame with wooden sheets ( 3 mm thickness ), and prusa MK2 3D printer to fabricate plastic handles .

Prusa MK2 3D printer

El Malky ML149 CO2 Laser Cutter

Design/Preparation Process

First : Sketch design in Fusion 360

I'm always had passion of history and arts especially our Pharaonic history . That's why I chose this design to present my passion .

My design is inspired of The Ancient Egyptian civilization . One lence presents The key of life and the other one presents a part of the Egyptian scarab . The Handles are inspired by Eye Of Horus

Frame Design

1- I opened fusion 360 , saved the file and chose create Sketch .

2- I draw The bridge first and began to draw the right lence then the left one .

3- After making sure that the sketch is fully defined , I tried to trim additional lines that I don't need in design . Unfortunately that causes a problem that the sketch became no longer defined . I tried to fix that but I couldn't solve it after all .

4- I extruded the sketch 3 mm and saved the sketch as a DXF file .

Handles design

1- I opened another file to draw the handles in a separated file.

2- I draw the standard handle with curved end then I draw the inspired part and made sure that the design is fully defined .

3- I Extruded the sketch 5 mm . Then I draw another rectangle on the inside face 5*5mm .

4 - I made sure it's fully defined and extruded it 5 mm. Created a circular hole in it 3 mm to fit the screw .

5- Saved the mesh as STL file .

Steps Of creating the front frame :

Steps Of creating handles :

Second : Preparing Laser cutting file.

1- I Inserted the design to laserwork after saving it as XDF file in fusion 360.

2- I mirrored the design horizontally and vertically then moved it to the corner.

3- at first I noticed that the design has an additional line that I didn't even draw in fusion 360. I didn't Know what went wrong and Asked my instructor ( Ahmed ) and fixed the sketch in fusion . After that I redid all previous steps .

4- I changed the line color to black and changed the speed to 40 and the power to 50 .

5- I exported the file as a RLD file and also as an AI file.

DXF file of glass's frame

Third : Preparing 3D Printing files .

1- I opened fusion 360 again , created a new sketch and draw my Handles. ( make sure you have the real dimensions as you won't scale your design up or down in cura )

2- This time I nailed it and the sketch became fully defined .

3- I saved the body as mesh then I chose STL extension and imported it in ultimaker cura .

4-I didn't change scale but rotate them and made sure they touch the heat bed . moved Handles to be closer but not touching .

5-I changed the fill to 20 % removed support and adhesion .

6- To finish the preparation process I saved the file as a G. code .

Handles STL file

Development/Implementation Process

Explain the development/implementation process of your assignment. How did you use the machine/tool to manufacture or implement the design of your assignment?

lv_0_20240115183620.mp4

This time I used the machine kinda on my own . I reviewed the RLD file and downloaded the file to the machine .

I fixed the wooden sheet ( 3mm thickness ) to the machine using wooden clips . Checked the nozzle height , changed the origin and draw a virtual frame to know if it won't move out of the sheet.

I pulled the cover of the machine and started the process after putting my phone on the cover glass to shoot tis video.

When the machine stopped I carefully tried to extract the part out of the sheet . One of the cut parts wasn't cut enough and causes a breach in the design .

lv_0_20240115172537.mp4

I checked the prepared file again then copied it to the SD card of the machine.

I changed the filament without help this time to change the color and I used a black PLA filament . I preheated the nozzle and waited till it became 215 c . Then I chose to extract filament , reload filament that I chose for my design ( the black on ) .

I waited till I saw the clean color of filament getting extruded then chose my file to get printed .

The file took 50 minutes and 9 grams.

Overcoming Challenges

What kinds of challenges or problems did you face while doing the assignment, tutorials, or exercises? How did you solve them? Did you ask for help from an instructor or peer? Please provide a link to the tutorial or article that you used to solve your problem (if any)

1 - During file preparation process , an undrawn line appeared . It wasn't easy to find out what's wrong with the sketch specially this line wasn't Shawn in fusion360 .

What did I do to solve this problem ?

I re-draw this part of the sketch and It worked !

2 - Faults of fabrication process .

The power of laser cutting machine was 50 and that wasn't enough to totally cut all parts . so, this part got broken while moving out of the wooden sheet .
First layers of the printed handles dried faster than expected . That happened because of the extruder cooler fan . The specialist ( Mona ) figured out what the problem was and fixed it and we got smoother process .

3 - While moving .

Small advice : assemble your project in the lab and take photos for documentation . You don't know if your project won't get broken while going home :( .

Final Project

How can you use the skills and knowledge that you've acquired this week in your final project?

I learned how to bring my ideas to life using 3d modeling by a software called Fusion 360 .

I design my first multi part design and think of how I would be able to assemble them together .

And finally that's my first time to use machines on my own .

I'm sure I'm taking baby steps towards skills I need to create my final project.

WOW!

What is the coolest thing that you've learned this week? What is something that you will never forget from this week?

These are the final results of my 1st. week in Maker Diploma .

The first project is a wooden cup coaster that made by laser cutting machine.

The second project is a mobile holder created by prusa 3D printer .

I'll never forget how fast I learned and how good my instructors were . They were always there for us any time and anywhere .

Weekly Digest [OPTIONAL]

Tell us about any other cool things that you've made this week: in the Hands-on activity, tutorial examples, exercises, or any other cool mini-project that you tried out aside from the assignment.

This week I had an ACC session that located in the American embassy . We used Macky Macky was so cool .

We used it to create a piano prototype that

ACC Session

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