I’ve always wanted to create my own pair of glasses featuring the arrow design from Aang’s head in Avatar.
For designing the assignment:
Fusion 360
Autodesk Fusion includes all the 3D design and modeling tools, as well as a complete CAM, CAE product development platform
For Laser cutting part:
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 Printing part:
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
DESIGNING STEPS:
Step 0 : Rule 0
We start the designing process with rule number 0, which was:
Open Fusion 360 Software
Create a new component
Save the file
Step 1:
We begin this stage of the work by taking the measure- ments of my actual glasses, so that the final model is adapted to my morphology and therefore wearable. Here are the different measurements that I was able to take:
frame front width = 140 mm
frame front height = 50 mm
lens height = 47 mm
lens width = 60 mm
bridge width =18 mm
Step 2:
After taking all the necessary dimensions, we can now start designing the front of the glasses in Fusion 360. Here are the steps I followed:
Open Fusion 360 Software
Create a new component
Create a new sketch (ZY plane)
Create a rectangle (length = 140mm and width = 50)
Create two small rectangles inside the large one (length = 47 mm and width= 60 mm)
Step 3:
At this stage, I personalized the design to make it more unique and visually interesting, so I added:
A small arrow symbol on the center of the frame, inspired by the iconic arrow on Aang’s head from Avatar
Pyramid shapes on both sides of the frame, to give it a bold and original style.
I added a little inclination using "Spline" and then I fixed them with the lock so that it doesn't move.
Step 4:
In this step, we create two holes on both sides of the front frame. These holes will later allow us to attach the arms using screws and securely connect them to the front frame.
Since we plan to use 3 mm screws, we designed the holes with a diameter of 3.3 mm. This extra 0.3 mm tolerance ensures that the screws can be inserted easily without forcing, and allows for slight adjustments during assembly.
Step 5:
Now that the design of the front frame is complete, the next step is to verify that the entire sketch is fully constrained in Fusion 360.
This means making sure that all shapes and lines are fully defined by dimensions and constraints, with no parts left floating or undefined.
A fully constrained sketch ensures stability, accuracy, and ease of modification later on.
In Fusion 360, we can confirm this by checking that all the sketch lines turn black (instead of blue), which indicates that the sketch is fully constrained.
Step 1:
As with the front frame, I began the arm design by measuring real-world dimensions. To do this, I used my own pair of glasses as inspiration and reference, ensuring that the final model would be both realistic and comfortable to wear.
Total length of the arm: 150 mm
Width of the arm: 5 mm
Average thickness: 4 mm
Step 2:
After taking all the necessary dimensions, we can now start designing the arms of the glasses in Fusion 360. Here are the steps I followed:
Open Fusion 360 Software
Create a new component
Create a new sketch (ZY plane)
Create a rectangle (length = 140mm and width = 50)
Create two small rectangles inside the large one (length = 7 mm and width= 50 mm)
Step 3:
In this step, we will create fillets for the arm design in Fusion 360. The fillets will smooth out the edges and corners, giving the arms a more refined look while also improving comfort and durability.
Step 4:
In this step, we design the small connecting parts at the front end of each arm. These parts will allow the arms to be attached securely to the front frame of the glasses.
The design includes a small extension with a hole that matches the screw size and position used on the front frame. This ensures proper alignment and a stable mechanical connection between the arms and the main frame.
Step 5:
In this final step, we create a symmetrical copy of the arm we designed, in order to complete both sides of the glasses.
To do this, we first create a construction plane with an offset in Fusion 360, this plane acts as the mirror axis.
Using the Mirror tool, we then select the entire body of the first arm and reflect it across the construction plane.
LASER CUTTING STEPS: Front Frame
The steps to follow to successfully print your design with the Laser cutting machine are:
Check the settings with the Fab specialist
Place the wood clamps on all four sides of the wooden piece to secure it in position.
Check the focus (the distance between the laser and the wood) using the reference tool.
Verify the frame of the design by pressing the “Frame” button.
Start the cutting process
When the cutting is finish Remove the model and clean it
3D PRINTING STEPS: Arms
Draft: 0.2mm
Infill density: 20%
Support: off
Adhesion: off(Our design is small and therefore does not require an adhesion tray)
Time: 78min<90min
Weight: 12g<30g
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
THE RESULT:
Picture 1
Picture 2
Picture 3
Yes, I asked the Fab Specialist for her opinion on my project, and she mentioned that the arms in my glasses design were a bit too heavy for actual eyewear. She advised me to make them lighter next time to improve comfort and practicality.
While I was printing my design on the 3D printer, the FabLab specialist Asma advised me to slightly enlarge the end part of the arm that connects to the front frame, because it was too short and might not provide a secure attachment.
The knowledge I gained this week will be useful for my final project, the rotating globe. For example, I can use the offset construction plane to design the upper part and then create its symmetrical copy.
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