Week #2 - 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)

potter vibes only :

Since I was 8, Harry Potter has been the movie of my life. I always dreamed of wearing his glasses, scarf — even holding the wand. And finally… the magic found me! ✨

So I decided to design my own Harry-style glasses — inspired by his iconic frame and lightning scar.

This image was my inspiration design! ✨

Tool Chain

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

Here's everything I used to complete the laser cut part :

I used Fusion 360 to design the frame from scratch — all the way to a laser-ready cut file (DXF) !

Then I exported the file to LaserWork, adjusted the parameters, and made sure the frame would cut exactly how I envisioned it!

Went with 3mm plywood for the cut—perfect match for the design !

I used the El Malky ML149 CO2 laser cutter to precisely cut my glasses frame!

Here's everything I used to finish the 3D part :

I also used Fusion 360 to design the glasses arms from scratch — all the way to a 3D-printable model!

Then I exported the file to Cura, adjusted the dimensions, profile, and infill to get a clean, ready-to-print result!

I used black PLA filament to match the full Harry Potter vibes!

Finally, I set everything up on the Prusa MK3 machine—and the magic began!

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?

laser cut summary ( before extrude ):

Started with two circles, each 48 mm in diameter, spaced 75 mm apart
Used the Line Tool to draw Harry’s iconic lightning scar.
Created a 5 mm offset to give the frame proper thickness.
Drew two screw holes with a diameter of 3.2 mm.

laser cut summary (after extrude ):

After finishing the sketch, clicked Finish Sketch.
Selected the Extrude tool (or pressed "E").
Highlighted the full glasses frame shape
Set the Distance to 3 mm for the frame thickness.
Made sure Direction was set to One Side and Operation to New Body.
Clicked OK — now the frame is 3D!

The file was saved as DXF format to be used with LaserWork.
Opened the design in LaserWork software.
Set the mode to: Cut
Speed was set to: 40

Power settings:

Minimum power: 40
Maximum power: 45

3D printing summary (before extrude ):

The arm was sketched using straight lines and arcs.
Total arm length: 134 mm.
Width (thickness): 5 mm.
Straight section length: 100 mm.
Curved end length: 34 mm.
Arc radii used: R20 mm and R2 mm (for smoother corners).
A circular hole was added near the base for the screw connection.
The sketch is fully defined with proper constraints.

3D printing summary (after extrude ):

The sketch was extruded by 3 mm to create the thickness of the arm.

A 2 mm fillet was applied to the edges to smooth and round them.
I used the Appearance tool to color the model ( plastic , glossy black )

Exported the file as STL format to open it in Cura.
Applied a mirror to the arm design.
Set infill to 10%.
Set layer height (resolution) to 0.2 mm.
Since the arm was thin and might break, set shell thickness to 2 mm.
Support was not needed.
Added a brim for better bed adhesion.

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?

laser Implementation :

After exporting the file in . ai format from LaserWork, we save it to a flash drive to transfer the data to the laptop connected to the machine, where we fine-tune the parameters further.

we need to secure the wood so it doesn’t move during the cutting process.

After downloading the file from the computer, we go to the machine, load the file, and adjust our origin and frame.

Then we start adjusting the focus, since it wasn’t set properly.

Once the laser cutting was done, I felt like the Harry Potter theme wasn’t complete yet — so I decided to add a touch of magic with some paint!

I think we are too close now !

voila 😍

3D Implementation :

we need first to prepare the bed by cleaning it with alcohol and tussle

After cleaning the print bed, we adjusted the setup in the 3D printer and kicked off the printing process!

The arms are ready — time to attach them to the frame and let the magic begin, just like Harry!

Wingardium Leviosa...

Let your ideas levitate just like this one! From sketch to spell — the magic is real.

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?

I showed the previous design to one of my teammates, and he suggested increasing the thickness of the lightning bolt section, as it was too thin and might break. So, I adjusted the offset from 3 mm to 5 mm — and the new shape came out thicker and much stronger!

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 struggled for three days trying to make my design fully defined — but I just couldn’t figure it out. So, I asked my friend Ebram for help, and he managed to fully define it for me!

Turns out, the angle between the lightning bolt line and the circle wasn’t set — and that’s why the sketch wasn’t fully defined.

shout out to @Ebram Gadelrb

Final Project

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

I'm really happy and proud that I’ve learned how to work with Fusion 360 and create something I love and that means a lot to me. After learning how to sketch in Fusion and how to make the shape defined using Fusion’s tools and all that, I feel ready to start the first step of my final project

WOW!

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

Title of Media

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.

Title of Media

Assignment Design Files

the frame . dxf

.plt

Arms . stl

.gcode

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