Week 2 - Journal

Machines 

Software 

Materials 

Designing the Eyeglasses Frame:

1. I began by watching all the uploaded tutorials to learn how to use Autodesk Fusion 360, which was completely new to me.

2. I searched online for design inspiration and found a creative eyeglass frame featuring a Minnie Mouse theme.

3. I started by modelling the left side of the eyeglasses.

4. I used circles to shape both the lens and the ear decorations.

5. I also added circular cutouts for screws (3.3 mm diameter) using the extrude feature with a negative value.

6. I applied the "Trim" tool from the Modify menu to clean and connect different parts of the sketch.

7. I used mirror option to get the right side of the eyeglasses.

8. Once the design was complete, I extruded the frame to a thickness of 2.5 mm, leaving space for the screw section.

9. I exported the design as a dxf file for use in RDWorks.

10. In RDWorks, I removed a line that wasn't able to remove it as fusion then set the power to 40 and the speed to 65.

11. Finally, I saved the file as a rld format, ready for printing with the laser cutter.

Designing the Sides of the Eyeglasses:

1. I started by imagining and sketching the eyeglasses, but later realized I needed to reduce the dimensions since I initially made the width 2 cm, which was too large.

2. I drew a rectangle for the left side and used lines to create curves, then extruded the shape to 20 mm to preview it. I found it too bulky, so I adjusted the dimensions to 100 mm in length and 10 mm in width.

3. After that, I added another rectangle on top of the extruded shape to create space for the screwdriver and used a trim option to cut it out.

4. I used fillet option for the sides of the eyeglasses. 

5. I exported the model as an STL file to use in Ultimaker Cura.
   In Ultimaker Cura, I set the following settings:

   • Layer resolution: 0.2 mm

   • Infill: 10%

   • Support: Normal (Touching build plate)

   • Adhesion enabled
     After slicing, the print time was estimated at 20 minutes, using 3 grams of filament.

6. I saved the file as gcode for printing.

7. Later, I used the mirror function in Ultimaker Cura to create the right side of the eyeglasses with identical features and saved it as a separate G-code file.

                    Using Fusion 360 to design the frame

Using RDWorksV8

 Using Fusion 360 to design the sides of the eyeglasses

Using Ultimaker Cura 

1- First step I booked a slot for printing and visited the lab to do.

2- The lab specialist reviewed my design, just advised to keep it as plt in case of any changes needed to be done.

3- We use 30 for speed and 50 for power. 

3- I then downloaded and saved it again.

4- Choose a wood sheet and placed it and fixed it from the sides.

5- Checked the focus of the machine 

4- I press start on the machine then press file then enter.

5- Adjusted the arrows and checked the area exactly where I want to print in.

6- Press origin then frame.

7- Close the cover of the machine and finally press start to cut my design.

1- After visiting the lab,

2- The lab specialist recommended modifying my file by adding the right side of the eyeglasses next to the left side in Ultimaker cura then using the "Arrange" function to ensure both sides are printed in the  same time.

3- I saved the file again in gcode format.

4- I prepared the printer by cleaning the bed before starting the print.

5- I selected "Unload" to remove the existing filament and chose a new color, then used "Preheat" to make removal easier.

6- I pressed "Load" until the new filament color appeared.

7- I inserted the SM card and selected my file.

8- I pressed "Start" to begin the printing process.

9- The printer bed began heating and adjusted the dimensions accordingly.

10- I checked the adhesion to ensure the design was properly attached to the bed.

11- After printing, I allowed the design to cool briefly before removing it from the bed.

12- Attached the sides to the frame done by laser cutter using screwdriver. 

I struggled with designing both sides of the eyeglasses because I had only created the left side and couldn’t replicate the right side exactly in Fusion 360 due to multiple overlapping sketches. So, I asked my instructor Yassin for help, and he suggested using the mirror feature in Ultimaker Cura—which worked perfectly. 

1- After completing the exporting and slicing of the eyeglasses frame files into G-code, I realized that each side of the frame would take 90 minutes to print, not both sides together. As a result, I had to redesign the model with smaller dimensions in Fusion 360 and reassess the printing time. Although it took me a while, I learned that it's perfectly fine to spend time refining a design, and that accuracy in measurements is essential for achieving the best results. 

2- Another challenge I encountered was not clearly defining my design from the start and found not easily to do after finishing the shape. Both my instructor and peers advised me to move the shape across different dimensions to better understand where adjustments were needed. From this experience, I learned the importance of defining the shape step by step rather than postponing it until the end. 

3- I saved each side of the glasses as one file and this would take two steps of printing, but the lab specialists advised me to add both files together using Ultimaker cura and it works easily. 

What I’ve learned in designing from scratch using Autodesk Fusion 360—even though it was my first time—will definitely support me in creating my final project more easily. I’m also now more comfortable using Ultimaker Cura and RDWorks, which will certainly be helpful. 

I learned how to use Fusion 360, which at first felt like a nightmare when I watched the tutorial videos. 

The most exciting part of this week was working together as a team to design, sketch, and print a unique bookmark that blended both wood and PLA filament.