Week 3

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)

For this week's assignment, I did not have a particular concept or idea in mind. I wanted to just create something functional that also looks good.

I started by conducting a google image search for some ideas.

This particular design stood out. I liked the symmetry and simplicity of the compartments. However, if i were to make it, I would use the space in the centre for sticky notes, and I would change the engraved drawings on the front.

Tool Chain

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

Softwares:

Fusion 360 for sketching
RD Works: preparing DXF for laser cutting

Machines:

Laser Cutter: El Malky ML149 CO2

Materials:

3mm plywood for laser cutting
M3 screws & nuts

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?

First, I did some quick planning and decided on all my dimensions and side names

4. Created a new component: B1

2. I opened a new file on Fusion and saved it. I started by creating my first component: A1 and sketching it

5. Sketched and extruded B1

3. Then, I copied and extruded A1

A1 & A2:

6. Started joining my components together but I realized that the B sides should only have one x-slot, and tabs on the other side, to join with the back panel.

7. Edited B1 and B2 to fix this. Closed the left x-slot and added a tab on the left

8. Joined my A sides abd B sides successfully

12. Constrained both components so that they are aligned with a gap of 80mm

15. Projected the bottom tabs to create the base

18. Cut the design and joined all components together + added a 2 mm fillet on some corners

9. Created a new component for C1 and repeated the same sketch as B1, with opposite sides for the x-slot and tab: x-slot on the left and tab on the right

13. Created a new sketch for the back and projected the tabs

16. Extruded the base

19. Created a blank sketch for each component to export as DXF

10. Joined A, B and C sides successfully

11. Inspected interference, to make sure that my components will fit properly

14. Extruded the back and joined with the rest of the components

17. Edited the back sketch and added a simple design using the circular pattern feature

Preparing the file for laser cutting:

Imported my 8 DXF files on RD Works and nested them as close as possible to each other on the workspace
Exported as DXF
Imported into RD Works:

Ensured the size and scale was correct

Adjusted the cut parameters: power and speed settings based on 3 mm plywood:
- Power 45% - Speed 40 mm/s

Clicked CTRL + A select all and check the dimensions to make sure the total size will fit the plywood sheet

Ran a preview to ensure all lines were assigned correctly.
Clicked "download" to send file to laser cutter and named my file PENHOLD
I rearranged the parts a few times to ensure everything fits on my sheet

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 Cutting

Placed and fixed 3mm plywood on bed.
Selected my file by pressing “File” button on machine and ensured my parameters are correct
Set the correct laser height to ensure it is in focus
Moved lens to top corner of plywood
Pressed “origin” to set start point
Pressed “frame” to check cut fits within sheet limits
Closed door and started machine
Removed parts after cut, confirmed proper size and clean cut

IMG_4690.MOV

Checking the parameters and framing

IMG_4694.MOV

Cutting process

Assembly process

Placing and fixing sheet + adjusting focus

Final cut pieces

Final assembled pieces

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?

While assembling my pieces, I remembered my instructor giving a tip on focusing on good sides versus burnt sides, and always using the good sides on the exterior of any project.

Otherwise, I can use alcohol to clean the burnt sides.

When laser cutting, the lab specialist helped me nest my pieces as my total cut was not going to fit on the plywood. In this process I went back and forth between editing the file on RD works and re-defining the origin and frame on the laser cutter.
It was a little like solving a puzzle to take up less material

Before and after nesting with less space consumed:

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?

When joining my components, I noticed that some parts did not fit properly (see images below), I went back to the self practice videos and projected the face.

Before watching the video, I was selecting the wrong sides, so the projection was never perfect. Instead of selecting the face of the tabs, I was selecting the inner parts.

Also, by looking though the interface of Fusion to try to find a solution, I discovered that I can constraint whole joined components, this helped me align them, and project the base properly.

These were the correct selected parts (in purple) for the project tool

I was having trouble with exporting and saving my files, on my Mac, since I cannot download the export as DXF plugin. A classmate, helped me and told me about a video on the Maker Diploma portal which explained this.

I was then able to successfully export my files as DXF, as individual parts.

Design Files

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