Week # 2 - Journal

1-Started With Circles at first

 2-Mirroring the circle

 3-offesting the circle using "Offset"

4- Finished sketching the frame… hated it instantly, so I built a new one! Turns out the first one was more “abstract art” than the reference proportions. 

5- Started again from Scratch

6- Developing the sketch

7-  refining the result to reach Fully defined sketch 

9- Made a parametric pattern starting with tiny circles in the center, then letting them grow like they’ve been hitting the gym, until they reach the border 

10- Pattern parameters I used 

11- Creating a fully define sketch for the sides 

12 -Extruded and filleted the sides 

13 -Drilled a 3.3 mm hole for the screw… because apparently, even screws need a comfy home 

14 -Adjusting the glasses model so it looks like the real thing — blue PLA for the sides and good old plywood for the frame. 

First, I exported the frame as a DXF file from Fusion using DFX plugin

I used RDWorks to prepare the file for the laser cutter, setting the parameters to:

• Speed: 40

• Power: 45

I split the parts into two sheets since the sheet size was 30 × 50 cm.
After opening my file on the lab laptop for a final check, I clicked Download to send it to the machine.

This time, I made sure to check and adjust the nozzle focus.
Using the machine interface, I followed these steps to start cutting:

1. Pressed the Esc button to exit any recent files.

2. Pressed the File button to browse, then used the arrow keys and Enter to select my file.

3. Placed my wooden sheet and secured it with clamps.

4. Moved the nozzle to the top-right corner of the sheet.

5. Pressed the Origin button to set the starting point, then the Frame button to preview the cut and confirm it was within the sheet boundaries.

Finally, I closed the machine doors and watched the magic happen!

Exporting the sides as stl from Fusion:

I began by transferring the g-code file to an SD card.
I selected the grey filament and loaded it into the printer.
The machine then preheated both the filament and the print bed.

Next, I inserted the SD card, chose Print from SD, and selected my file.
The printer moved around the bed to calibrate, then started printing.
I monitored the first 3–4 layers closely to spot any errors early.

Importing the stl File into Cura these are the settings :

Rafts: No

Supports: No

Resolution: 0.2 Draft

Infill: 10% Rectilinear (lines on Ultimaker Cura)

Nozzle Temp: 215℃ 

Bed Temp: 60 ℃ 

I got feedback on my first pair of glasses, and… yeah, they didn’t exactly pass the requirements because I used traces. So, after coordinating with the instructor, I designed a second pair that fixed the issues from the first one. As for the pinhole glasses idea — I spotted it online, thought it was pretty cool, and decided to give it a try. 

I messed up a lot here , these photos are from the first glasses I made, which completely went against the requirements (especially the tracing part). After countless mistakes with scale, proportions, and even 3D printing, I decided to start fresh and design a new pair from scratch. 

I messed up a lot here , these photos are from the first glasses I made, which completely went against the requirements (especially the tracing part). After countless mistakes with scale, proportions, and even 3D printing, I decided to start fresh and design a new pair from scratch. 

I made several mistakes in this assignment, which I’ve learned from:

1.My first mistake was not taking the nuts into consideration.

2.The walls around the screw holes were too thin, making them weak and easy to break.

3.I made a major mistake while using Cura — I exported only one hand and copied it in Cura instead of mirroring it, which led to a very funny result.

4- As it appears here that the two hands are similar .

The new glasses came with their own challenges  like pattern making, which was completely new to me. 

…and after many attempts, it finally worked! 

I watched this Tutorial and it helps me alot 

Tutorial Link 

After printing the Prim was attached to the sides of the glasses 

…and the fab lab specialist suggested using these tools to clean it. Turns out, they also work like magic for making manual fillets — pretty cool bonus! 

Title of Media

Now  it's clean and neat !

The Final Output 

I'll use Nut and bolts and make joints always before processing to laser cutting or 3d printing 

Files