Week 3- Journal

Task's Idea:

I browsed the internet for inspiration then picked this one and adjusted it according to my desired design

Tools:

First, the software systems I used were:

AutoDesk fusion 360

Ultimaker cura

LaserWorksV6

The materials I used were:

3mm plywood

Generic PLA Filament

Screws and nuts

The devices I used were:

Elmalki laser cutter

Prusa i3 mk2 3D printer

Screw driver

Design Process

Explain the design and/or preparation process of your assignment. How did you use the tool or software to design and/or prepare your assignment before fabrication/implementation?

Sketching:

Now lets get to the design part:

Make sure capacity of editable projects is as minimal as possible.

Save file and name it

I named it pen and pencil holder

Create New component.

I created the components and named them based on my sketches on paper.

Here are all my components

Activate first component by clicking on that dot then select create sketch

Draw the sketch then select finish sketch

Now extrude downwards 3mms

Now repeat that process through the remaining components

Back sketch is now fully defined

Finish sketch and extrude 3mm

Right side sketch is fully defined

now finish sketch and extrude

I joined the three components and checked for interference

no interference detected

Left side done the same way as right side.

Shelf sketch is now fully defined

Finish sketch and extrude 3mm

Pen Holders shelf sketch is now fully defined

Finish sketch and extrude 3mm

Pen holders front sketch is now fully defined

Finish sketch and extrude 3mm

Pen Holders separator sketch is now fully defined

Finish sketch and extrude 3mm

The same is done to the other separator.

Drawer base is now fully defined

Finish sketch and extrude 3mm

Drawer front sketch is now fully defined

Finish sketch and extrude 3mm

The same is done to the drawer back.

T- slot dimensions in the drawer back

It's fully defined

Drawer right side is now fully defined

Finish sketch and extrude 3mm

The same is done to the left side.

Paper clips base is now fully defined

Finish sketch and extrude 3mm

T- slot dimensions in the base

Paper clips side1 is now fully defined

Finish sketch and extrude 3mm

The same is done to the other side.

Paper clips front is now fully defined

Finish sketch and extrude 3mm

Paper clips separator is now fully defined

Finish sketch and extrude 3mm

Fully defined sketches of the modified bracket:

Bracket sketches Extrusion:

Here's our bracket. joined to its place.

Join all compartments together

Always check for interference

no interference detected

Laser cut design files:

Base

Pen Holders shelf

Back

Pen Holders Front

Left Side

Pen Holders Separator

Right Side

Shelf

Drawer base

Drawer Back

Drawer Front

Drawer Side

Paper clips Base

Paper Clips Separator

Paper clips Sides

Paper clips Front

3D design design file:

Bracket Stl file

Woah!!!! we're finally done with the design process🎉🎉

Development 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?

Laser cutting:

Open laser works software, import your files and make sure of your parameters " power and speed are adequate

I chose cut:

speed 30

Power 50

And scan:

Speed 330

power 20

Press the download button, from the machine, pressed file, choose the file, set the origin point then press start

3D printing:

Choose print from the printer panel and from media choose the file, then press OK.

Bed and nozzle temperatures are set to 60, and 215 C

After 12 minutes, my 3D print was done

Modified bracket installation into my final product

M3 screw and nut installation into the T-Slot to join the drawer components together.

Assembly of my components. We are finally done.

Unfortunately It didn't meet the assignment requirements, so we are going to make another one.

Ideation:

The idea was to make a pencil holder that may rest on a flat surface and contains at least 2 compartments To be designed and assembled using Fusion360

So I did some browsing for inspiration, I decided to make a pen holder compartment and another compartment for sticky notes.

Tools:

The software systems I will use are

Fusion 360

LaserWorksV6

The materials I will use are

3mm plywood

Screws and nuts

The devices I will use are

Elmalki laser cutter

Screw driver

Design Process:

Free hand sketch on paper to visualize the design

Open Fusion 360, Save file and name it

I named it New pencil holder

Create New component for the base and name it then create a sketch in it

Base dimension is 140x 70

creating dimensions of holes and slots for the other component's t-slot to rest and for the screw to pass

Sketch is now fully defined

Now finish sketch and extrude 3mm

The first component is done

create a new component for the front part,name it then create a sketch in it

Create t-slots with the adequate dimension
Create cross slots

Now the front sketch is fully defined

Finish sketch and extrude 3mm

The second component is done

create a new component for the back, name it then create a sketch in it

Back Dimension is 140x100
Create t-slots with the adequate dimension
Create cross slots

Now the back sketch is fully defined

Now finish sketch and extrude 3mm

The third component is done

create a new component for the left side, name it then create a sketch in it

Left side dimension is 70x100
Create t-slot with the adequate dimension
Create cross slots

Now the left sketch is fully defined

Now finish sketch and extrude 3mm

The forth component is done

create a new component for the middle side, name it then create a sketch in it

Middle side dimension is 70x100
Create t-slot with the adequate dimension
Create cross slots

Now the middle side sketch is fully defined

Now finish sketch and extrude 3mm

The fifth component is done

create a new component for the right side, name it then create a sketch in it

Right side dimension is 70x100
Fillet one corner to give it a round look
Create t-slot with the adequate dimension
Create cross slots

Now the right side sketch is fully defined

Now finish sketch and extrude 3mm

The sixth and final component is done

Now let's join the components together and change their appearance so they would look like wood

Press J letter on keyboard then choose which two points, lines or faces will be joined together

Here it is, the first two components are joined together. Repeat this for other components

All components Joined together.

Change the appearance to have a wood-like appearance.

After rendering here's what it looks like.

Now Let's save our components as dxf

You can save your project by selecting the face you want to save and from create toolbar, choose save dxf for laser cutting

Do the same for the remaining components

Here's the link to the DXF files

Dxf files

Next you need to open LaserWorks software, import your files and adjust the cut parameters. I set the speed to 30 and the power to 50

I added some engravings of a show I love to the file.

I imported their PNG files to convertio and saving them as dxf

then imported it into LaserWorks

I then exported my file after naming it as ai and rld.

Here are the design files:

ai file

rld file

Development Process:

Press the download button, from the machine, press file, choose the file, set the origin point then press start

It took 9 minutes and 37 seconds to be done.

Assembly of the components using M3 screws and nuts

Here's the final outcome🎉

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)

To design this slot in the exact Location in the opposing component , I extruded cut through its joint which led to the joint's deletion.

I solved it by:

Deleting that extrude feature from the timeline bar after saving the other component "Back"

After deleting that extrude feature, it will show again ready to be converted to DXF

So Next time, We Shouldn't Extrude when two components are joined together without making sure that no undesired changes has happened.

Another challenge I had was that I had a problem with saving the faces as dxf

I solved it by:

After clicking ok and cancel i found the component laser path, selected its sketch and saved it as dxf

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