Week 1 - Journal

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)

The assignment for this week focused on the comprehensive process of preparing digital design files using specialized software tools, followed by the practical fabrication of physical models through the application of two advanced manufacturing technologies: 3D printing and laser cutting. This task required us to understand and apply the principles of digital design, convert our ideas into suitable formats for production, and utilize the appropriate machines to bring our virtual models into the real world.

When I visited 3axis.co, I liked the design of a tree model that serves as a coffee or tea cup coaster, which I then downloaded to make my laser-cut model.

As a big drinker of drinks with caps, and it annoys me to reopen it every time, so it would be more practical to have a bottle opener keychain, so During my visit to the website Thingiverse.com I choosed this design for my 3D printing model.

Tool Chain

Which software/machines/materials did you use in the assignment? Why?

For laser cut assignment:

3axis.co

The website I used to found the design

RDWorks V8

The software that allowed me to modify the design and add a circular base

El Malky ML149 CO2

The Laser cut machine used at FabLab Egypt

Plywood

the wood used at FabLab Egypt

For 3D printer assignment:

Thingiverse.com

The website I used to found the design

Ultimaker Cura

the software that allowed me to slice the design, modify the size as well as the quality

Prusa i3 mk3

The 3D Printers machine used at FabLab Egypt

PLA filament

The types of filaments used for the assignment

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?

3D PRINTING STEPS:

We will describe the different steps we followed to 3D print our model in the form of stages:

I used Thingiverse.co, an open-source CAD platform, to find a Bottle Opener model and downloaded the file in .STL format for 3D printing.
Then, I used the slicing software Ultimaker Cura to convert the STL file into G-code for 3D printing.

3. I adjusted the design settings before printing.

Scale: X=41mm, Y=59mm, Z=21mm
Infill: 10%
Support: Tree support
Adhesion: to prevent warping.
Layer Height: 0.2

4. Finally, making sure that the time and grams are suitable for the requirements.

weight: >10g
printing time : >90min

LASER CUTTING STEPS:

We will describe the different steps we followed to laser cut our model in the form of stages:

I used 3axis.co, an open-source CAD platform, to find a Tree model and downloaded the file in .DXF format for the laser cutter.
Then, I used the slicing software RDWorks to convert the Tree design file into .RLD for Laser Cutting.

3. I adjusted the design settings before cutting.

Scale: X=100mm, Y=100mm
Added a circle of the same size so that it becomes a cup coaster.
cut(black):

- Speed:20 -Power:50

SpeedCut(Green):

-Speed:300 -Power:25

4. Finally, saving the file in .RLD format to be printed.

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?

3D PRINTING STEPS:

Download the .gcode file on the Prusa machine

The steps to follow to successfully print your design with the Prusa 3D machine are:

Check the settings with the Fab specialist
Clean the print bed
Use alcohol and a cloth to clean the printer bed to ensure proper adhesion
Check the filament
Make sure the correct filament color and type is loaded and properly inserted in the printer
Start the printing process
Select the G-code file and launch the print
Remove the model and clean it
Once the print is done, carefully remove the supports and take the finished model from the bed

LASER CUTTING STEPS:

1. Check the settings with the Fab specialist
  Verify the key machine settings:
Cut (speed=40, power=45)
Scan (speed=300, power=25)

1. Upload the file to the laser cutter
  Transfer the design file (.RLD) into the laser cutting machine.
2. Secure the material
  Select the uploaded file on the machine and fix the wood firmly on the cutting bed using connectors
3. Set the laser starting point
  Position the laser where the cut should begin and use frame to make sure the design fits within the available space
4. Adjust the lens height
  Check the vertical distance the lens and adjust it using a reference tool to ensure proper focus
5. Start the cutting process
  Once everything is ready, start the cutting
6. Wait for smoke to clear
  After cutting is complete, we wait for the smoke to clear and open the machine
7. Clean the final piece
  Wipe the burnt edges of the wood with alcohol and a cloth

THE RESULT:

3D printing part

Laser cut part

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?

During my 3D printing session at the FabLab, I initially used the normal support option for my F16 model. However, it didn’t work well because my design had very small details that would not be properly printed. The Fab Specialist Eman suggested switching to the tree support option in Ultimaker Cura, which was more suitable for preserving those fine details.

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?

I was led to research when tree supports should be used in 3D printing, and I learned that they are ideal when you want to remove the support easily after printing or when the support is needed in interior spaces where traditional supports would be hard to remove.

Final Project

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

As part of my final project, a rotating model of the planet Earth, the knowledge I've gained about using tree supports in 3D printing will be very useful.

This type of support is particularly suitable for curved and complex shapes, such as those of a globe, as it allows for easy removal after printing and prevents damage to fine details. This will allow me to produce a cleaner, lighter, and more finished model, while reducing post-processing time.

WOW!

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

When I arrived at the FabLab, what impressed me the most was the presence of small clamps used to hold wood or plywood in place during laser cutting. We even have them in different sizes, such as 3 mm and 6 mm.

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 Saturday, we worked on creating a lamp using cardboard (low fidelity). I teamed up with my partner Fatima to first search for a good design on the Internet and then try to reproduce it using cardboard.

Title of Media

Assignment Design Files

Pocket Coin-Op Bottle Opener [STL]

Laser Cut Tree Of Life Celtic Style Wall Art [DXF]

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