Week #3 - Journal

I used Fusion 360 to create a custom design inspired by the one I found on the website.

After designing it on Fusion, I exported the file to LaserWork to adjust the parameters I’ll use for the laser cutting machine.

I selected 3mm plywood as the material for laser cutting my design.

Finally, I used El-Malky’s laser cutting machine to bring the design to life.

I started the sketch by drawing a rectangle from the origin with the dimensions shown in the picture. Then, I created the T-slot opening and added two tabs for better stability. After finishing, I copied and pasted the same side.

After creating the sketches for all the sides and joining them, I sketched the bottom panel. I used the Project tool to select the parts I wanted to project, then drew the screw holes.

I sketched the holder’s side and added a T-slot opening at the bottom with the dimensions shown in the picture. I also copied and pasted the same shape.

I made the middle divider with the same dimensions but reduced 3 mm from each side so it would fit comfortably inside the box. I also added a bottom tab for secure attachment.

The front and back side were extruded by 3mm . 

the bottom part was extruded with 3mm 

the middle part 3mm extrude 

left and right side 3mm extruded also 

added the left side to the back part and they joint perfectly 

right side with the left and back parts 

now we add the middle part 

final joint was the bottom part 

I exported the the whole components to laser work using DXF for laser .  

opened the DXF files on laserWork and adjusted them correctly  

I entered the parameters for the Speed cut: 

• Cutting speed: 300

• Power: 45

And the parameters for the cut were : 

• Cutting speed : 20

• Power 60 - 65 %

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.

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

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

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

At first, I designed it using only tabs to secure the holder, but I noticed that the joint wasn’t holding properly in Fusion. So, I decided to cut it and see exactly what the problem was, knowing that the tab dimensions were 20×4 mm on all sides.

Here in the joints, the problem is that they’re not fitting together—there’s some looseness between them.

Here, after I cut the shape, I found that the slots were larger than the tabs, and I hadn’t made any T-slots or anything else to secure the shape apart from these tabs.

The issue was : that I made the thickness 4 mm, while the actual wood thickness is 3 mm, so it ended up being loose.

The solution is :to make the thickness 3 mm on all sides.