Week 2 - Journal

Materials

Software

Machines

Work flow: New component > Sketch > Extrude > Solid > Hole creation > Export *DXF > LaserWork  > *plt

• I created a new sketch on the front plane.

• I drew the outline of the cat-eye lens shapes.

• Added:

  • Nose bridge

  • Inner lens cutouts

  • Holes for attaching arms

• Fully dimension the sketch

• Finish the sketch

• Export as DXF for laser cutting

Work flow:  New component > Sketch > Extrude > Solid > Hole creation > Export *stl >  Cura

• I created a new component for each side arm.

• I designed curved, comfortable arms with thickness of 7 mm for the side facing the frame, and it gets 50% thinner till it reaches the curvature that pass over the ear. 

• I extruded the rectangle and added some chamfers to add some curvature to the sides of the body.

• I added a screw holes to match the front frame.

• I checked the fitting of the screw and the nut using the joint command.

1) I began by selecting the cat-eye style as my design theme. Using a reference photo of standard glasses frames, I sketched the front frame outline using Fusion 360. The proportions were carefully measured to match standard eyewear dimensions for bridge width, lens height, and temple spacing.

2) The finalized frame 3D design was exported as a XDf file and imported into the laser cutting software. Cut lines were assigned with the following parameters:

• Laser Mode: Cut

• Speed: 40 mm/s

• Power: 45%

3) I placed the chosen plywood material on the machine bed and adjusted the focus height to match the material thickness.

4) A small test pulse was run to verify the settings and ensure clean cutting without burning. Once confirmed, the file was sent to the laser cutter using the download command.

5) The laser cutter was started, and I monitored the process closely for accuracy and safety.

6) After cutting, I removed the frame parts, cleaned off any residue, and lightly sanded the edges for a smooth finish.

1) The side arms were designed in a Fusion 360 with precise hinge holes to align with the plywood frame. A hidden fastening method was incorporated into the design, allowing the screw and nut to pass through the frame’s hole directly into the temple piece, concealing the hardware inside for a cleaner look.

2) The 3D design was exported as an STL file, sliced in 3D printing software Cura, and printed using PLA filament. The 3D printer built the arms layer-by-layer, producing durable and lightweight components.

3) The 3D printed arms were aligned with the plywood frame’s hinge points, and the screws were inserted through the frame’s holes directly into the temples, where the nuts were secured inside and hidden from view. This created a neat and seamless connection.

The hinges were tested to ensure smooth pivoting, similar to standard eyeglasses.

Final Check & Adjustments

The assembled glasses were inspected for symmetry, comfort, and overall aesthetics. Any minor fitting issues were corrected, completing the mixed-material cat-eye glasses prototype.

This was my first time creating a complete design in Fusion 360 for both the laser-cut frame and the 3D-printed side arms, unlike the first week when we used open-source files that were already production-ready. One challenge I faced was applying constraints to make the sketch fully defined. Initially, I was using too many constraints, which made the design harder to edit. After discussing this with Menna and practicing more, I learned how to minimize the number of constraints while still keeping the sketch fully defined. 

The coolest thing I learned this week was how to design an entire product from scratch in Fusion 360 and prepare it for two completely different manufacturing methods — laser cutting and 3D printing — all from the same CAD model. It felt rewarding to see my design go from a digital sketch to a physical object with mixed materials.

Something I will never forget is the breakthrough I had with constraints. At first, I overloaded my sketches with too many constraints, making them hard to adjust. After discussions with Menna and more practice, I learned how to keep the sketch fully defined using only the essential constraints. I’ll also remember breaking my old habit of creating a new sketch for every tiny element, and instead learning to combine related features into one sketch for a cleaner, more efficient workflow.