Week 2

Cool Glasses

Ideation

INSPIRATION

This week we are going to design and fabricte a cool glasses to wear but mixed between laser cutting and 3d printiing.

So I chose these glasses to start design it myself on fusion360 and i find it a cool nerdy glasses to wear.

So i decided to make the frame by laser cut and the arms of the glasses by 3d pint PLA filament, so let's see how i started to design it.🤓

Designing LASER CUTTING parts

Tool Chain

I used the cad program fusion360 to design the glasses, then i prepared the file of the glasses frame on RD works software to cut it on El Malky ML149 CO2 Laser Cutter, and also used Cura to prepare the arms of the glasses to print it on Prusa

Fusion360

Laser wok software

cura software

Polywood

PLA filament

El Malky ML149 CO2 Laser Cutter

Prusa i3 MK2

Design/Preparation Process

1- First i started to draw the circles:

a circle of a diameter (50mm) and then make offset for drawing anothen circle inside of a diameter (40mm).
then i started dviding these circle into 1/3 parts to trim one of them as shown.
after trimming this part i closed the circles edges by drawing a small line from the point of the insider circle to the point of the outer one.
i mirrored this part before adding the frame extention from the side but i advice you to draw it first before mirroring the frame.👌
then i defined the circles by giving them a dimentions.

2- Second i drew the extention of the frame in the side:

from tow points on the outer circle side i started to draw two lines of (7mm) and far from the origin point by (2.5mm) so they are far from each other by (5mm).
then i drew a 3-point arc between the ends of the two lines with a radius of (2.5mm).
then i trimmed the line between the extention and the circle.

3- Drawing the screw's place:

and here i started to draw a small circle of a diameter (3mm) for the screw's place in the frame and i made its central point alighned with the cintral point of the line obove it to place it in the middle.
finally i mirrored the extention part to the other side.

4- Drawing the middle part of the glasses frame:

i made an upper (15.5mm) radius 3-point arc between the other edges of the small circles and a lower (10mm) radius 3-point arc from the other edges of the bigger circles.
as shown in the picture i also made a (1mm) fillet for the free edges above.
i also defined all these parts relating to the origin point.

5- I finally press E shortcut to extrude the galsses frame for (3mm), all the frame without the nail's circle.

6- Here i choose the wood color from Modify then Apperance.

Designing 3D PRINTING parts

7- Drawing the arm of the Glasses:

started by drawing a (100x4mm) rectangle then define it to the origin point.

8- Then i drew two 3-point arcs starteing from the two points of the rectangle's right side.

the upper arc is (8mm) radius and the lower arc is (12mm) radius.
also here i close the two arcs by connecting their free points together by a small line.
then i chose fillet comand to make (2mm) fillet for the edges.

9- Here i drew the extention part of the arm :

i drew a small 7mm line and another 4mm line to attatch them to the arm.
and then i made the sketch fully defined.

10-Hree i extrude the hole arm (3mm) and them extruded the small extention part by (7mm).

11- Drawing the screw's circle:

first make a new sketch and choose the face of the part we want to draw the circle on.
start drawing a circle of (3.1mm) because we will print it 3D so the hole might be smaller if we make it 3mm.
and i defined it to the origin and made a distance of (2mm) between it and the tow sides of the part i drew it on.

12- Here i started to make a hole in this circle by choosing Hole comand and then change the Extents to ALL, then i made the hole of (3mm).

13- Here's the hole i made.

14- Now the frame and the arm is readdy.

15- save the DXF file of the glasses frame by write click on its sketch and click on save as DXF.

16- And save the STL file of the glasses arm by write click on the body of it and choose save as mesh then choose STL Binary format and click ok.

Implementation/Fabrication

Fabrication on the 3D printer

1- I opened Cura and imported the STL file of the glasses arm and then I made a copy for it and adjusted it to mirror it to the original one.

2- Here i adjusted the parameters :

wall thickness = 0.8mm
layer height = 0.3mm
infill density = 20%
infill pattern = grid

3- Then i made slicing to see thet it will take a time = 21 minutes and 4g of the PLA.

then i clicked on sve to disk to save the file as G-code.

4- adjust the printer on the color you want ( i used white) then upload the G-code file from your SD then start to heat the printer and once it's ready start printing.

This is after finishing printing the glasses arms.🤩

Fabrication on the Laser cutter

1- I wanted to add some touches on the glasses frame: 🙈

so i used the circle tool on laser work software to draw them before fabrication.

then i downloaded the file after adjusting the speed and power to the machine.

i adjusted the machine to start from the black color so it can start to make the speed cut of the circles then the pink color to cut the frame:

Black (min power = 20 , max power = 25 & speed = 300)
Pink (min power 50 , max power = 55 & speed = 30 )

2- Here i show you the file after i uploaded it on the laser cut machine after adjusting the speed and power.

After finishing fabrication 🤓

Final Project

Glasses frame DXF file

Glasses hands G-code file

Overcoming challenges

The challenge for me here was that i forgot to make the place of the screws in the PLA glasses hands bigger, because in 3D fabrication this hole might be smaller than it was in the design on fusion360 when we print it in plastic, so i didn't realise that before printing so in the result the screws were hard to put.
So, i advice you to make the circle dimention of the screw hole bigger by 2mm at least than the one in the wooden part of the glasses frame.
Also another challenge for me that after i fabricated the glasses, they were not fitting on my face cause the dimentions were a bit smaller than it should be.
So i advice you to make the dimentions a little larger than mine.
I overcome this challenge by switching the glasses arms' places to give me some space for the glasses size.

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