Embedded Files
Ideation
Ideation
Tell us about your assignment's idea for this week. Why do you care about this idea? What inspired you? (Please include images or links to sources of inspiration)
Tell us about your assignment's idea for this week. Why do you care about this idea? What inspired you? (Please include images or links to sources of inspiration)
For this week's assignment, I designed a castle-themed pen holder in Fusion 360. The design includes two compartments: one with four walls for pens and rulers, and another with three walls for sticky notes. At the center between the two compartments, I placed a standing archer silhouette—symbolizing a guard defending the castle. The archer figure was inspired by the Zamalek SC logo, a symbol I deeply admire and associate with pride and resilience.
Tool Chain
Tool Chain
Which software/machines/materials did you use in the assignment? Why?
Which software/machines/materials did you use in the assignment? Why?
Materials
3mm Polywood sheet
(2X) 3M screw and nut
Software
I used the Inkscape software to prepare the XDF of the archer man.
For the LASER cutting task, I used RDWorks software to prepare the XDF and rld files
To make 3D models
Machines
LASER cutting machine
LASER cutting machine
Design/Preparation Process
Design/Preparation 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?
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?
Design Planning & Inspiration
Design Planning & Inspiration
The design includes two compartments: one with four walls for pens and rulers, and another with three walls for sticky notes. At the center between the two compartments, I placed a standing archer silhouette—symbolizing a guard defending the castle.
Fusion 360 Design – (Laser Cutter)
Fusion 360 Design – (Laser Cutter)
Work flow: New component > Sketch > Extrude > Solid > Export *DXF > LaserWork > *plt
I created a new sketch on the front plane.
I drew according to the dimensions I set in the design.
Added some features
Fully dimension the sketch
Finish the sketch
Export as DXF for laser cutting
Front side (fully defined sketch)
Front side extruded
Back side (fully defined sketch)
Front side extruded
Left side (fully defined sketch)
Left side extruded
Right side (fully defined sketch)
Right side extruded
Right side (fully defined sketch)
Right side extruded
Left side of the sticky notes compartment
Right side of the sticky notes compartment
Back side of the sticky notes compartment
Joining the components using the Joint command
Projecting the tabs using the project command
Base of the two compartments. The projected tabs are shown in the base and extra tabs were created for the archer to be fixed in the middle of the two compartments.
The exact places of the archer was verified using the RDWorks software.
Components assembly
Assembly of the two compartments
The base was extruded and the tabs places are shown
The base was extruded and the tabs places are shown
The archer man was imported to the design to visualize the whole design.
The fun part!! [Zamalek theme was applied]
I added extra red bodied on the faces to visualize the final look I want to make by painting the faces after the laser cutting.
Laser cutting pararmeters
I imported all the faces as *.dxf file into RDWorks to determine the parameters as shown in the image
Laser Mode: Cut
Speed: 40 mm/s
Power: 45%
Laser Mode: Scan
Speed: 300 mm/s
Power: 25%
I saved the files as *.plt to be processed by the LASER machine
Development/Implementation Process
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?
Explain the development/implementation process of your assignment. How did you use the machine/tool to manufacture or implement the design of your assignment?
1) I began by selecting a castle theme as my design concept. Using Fusion 360, I sketched the base and walls, creating two compartments: one fully enclosed with four walls for pens and rulers, and another with three walls for easy access to sticky notes.
2) The finalized 3D design was exported as a DXF 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 laser cutter 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 cuts 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 pieces, cleaned off any residue, and lightly sanded the edges for a smooth finish before assembling the compartments.
Community of Learning
Community of Learning
Did you ask for feedback? What are the ideas that others have contributed or suggested? What was someone else’s idea that you built upon? How did you help your peers? How did your peers help you?
Did you ask for feedback? What are the ideas that others have contributed or suggested? What was someone else’s idea that you built upon? How did you help your peers? How did your peers help you?
I had trouble using the projection command to project my side tabs onto the base. It didn’t work at first, but with Menna’s help, I was able to get the projection done correctly.
I couldn't be able to make the projection on the base.
Overcoming Challenges
Overcoming Challenges
When you got stuck, what/who did you turn to? At what point did you have to pause to research or learn more before moving on? What are some mistakes, pitfalls, or challenges that others can avoid if they were doing this assignment?
When you got stuck, what/who did you turn to? At what point did you have to pause to research or learn more before moving on? What are some mistakes, pitfalls, or challenges that others can avoid if they were doing this assignment?
I was really puzzled trying to get my sketch fully defined. Everything looked perfect—black lines everywhere and all constraints in place—but it still wasn’t complete. After some digging, I found a tiny, stray point way out in the distance that was causing all the trouble. Deleting that little troublemaker finally solved the problem!
A zoomed out sketch to show a tiny, stray point that was causing the sketch to not be fully defined!
Final Project
Final Project
How can you use the skills and knowledge that you've acquired this week in your final project?
How can you use the skills and knowledge that you've acquired this week in your final project?
This week, I designed a castle-themed pen holder in Fusion 360 with two compartments—one for pens and rulers, and another for sticky notes—featuring a standing archer silhouette inspired by the Zamalek SC logo. I added LED lighting for a glowing effect, which taught me to value aesthetics alongside functionality. I improved my CAD workflow by using fewer, more efficient constraints and combining related features in single sketches. On the manufacturing side, I prepared files for laser cutting plywood, tested material settings, and used tab-and-slot assemblies for precise fitting. These skills will help me create a cleaner, more precise, and visually appealing final project.
WOW!
WOW!
What is the coolest thing that you've learned this week? What is something that you will never forget from this week?
What is the coolest thing that you've learned this week? What is something that you will never forget from this week?
The coolest thing I learned this week is how to blend beauty with functionality. My pen holder looks great as a decorative piece, even without pens or sticky notes!
Assignment Design Files
Assignment Design Files
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