🔮 Inspiration: Inspired by Mike Wazowski (مارد وشوشني) from Monsters, Inc. A fun, quirky, one-eyed character known for his iconic round features and bold personality.
💡 Why I Care:
I love imaginative, playful designs with personality.
It allowed me to express my creative side while applying technical design skills.
I wanted glasses that reflect joy and uniqueness: not just function.
🧠 Creative Direction:
I imagined what Mike would wear if he had two eyes, futuristic, playful glasses that feel "alive."
The design plays with asymmetry and bold circular shapes to mimic his iconic eye and green color.
Laser Cutting
Software: LaserCAD
Machine: Malky ML64 CO₂ Laser Cutter
Material: PlyWood
I used Plywood because it’s affordable, easy to cut, and ideal for creating detailed designs like logos or small prototypes.
LaserCAD
It easily imports the .DXF file I exported from Fusion 360, preserving the 2D geometry exactly as designed.
3D Printing
Software: Ultimaker Cura
Machine: Creality Ender 3 3D Printer
Material: PLA
PLA was chosen because it’s beginner-friendly, environmentally friendly, and works well with the Ender 3 for producing smooth and accurate prints.
Cura
Used for slicing the.STL files of the side arms for 3D printing.
Ultimaker Cura
PLA
Creality Ender 3 3D Printer
LaserCAD
Malky ML64 CO2 Laser Cutter
Plywood
Fusion 360
Used for both 2D and 3D design (front frame & side arms).
Chosen because it’s a professional CAD tool with strong sketching, parametric modeling, and easy export options for both laser cutting (.DXF) and 3D printing (.STL).
Enabled precise control, full sketch definition, and the use of design features like Fillet and Chamfer.
Sketch Creation:
Draw two circles of specified diameters.
Trim the unwanted sections between the circles to form the desired profile.
Extrusion Process:
Use the "Extrude" feature to give the 2D sketch a 3D volume.
Sweep Operation for the Hand:
Define a path or guide curve.
Use the "Sweep" tool along the defined sketch to create the curved structure for the hand.
Fillet for Smoothness:
Apply the "Fillet" tool to smooth out the edges for a more comfortable fit while wearing.
Mirroring for the Opposite Side:
Apply the same process for the left-hand side but in the opposite direction to ensure symmetry.
Left Hand Side
Right Hand Side
Face of Glasses
Slicing Software (Ultimaker Cura):
Imported the STL file into Cura.
Oriented the model properly on the build plate.
Printer & Quality Settings:
Selected the printer profile: Creality Ender 3 Pro.
Used the Standard Quality – 0.2mm resolution preset.
Custom Print Settings:
Set infill density to 10% with a cubic pattern for added strength.
Enabled tree supports to handle overhangs.
Adjusted shell thickness for better durability.
Preview & Final Prep:
Used Preview mode to visually check each layer of the print.
Reviewed estimated print time and filament usage.
Export & Print:
Exported the G-code file.
Saved it to an SD card for printing on the Ender 3 Pro.
Dimesnsions
Lens Width
Dimension of Support between 2 Lens: 19mm
Dimension Width: 159.499mm From the first circle of side support to the other side support
Dimension Hight: 50.09mm
Next, I adjusted the dimensions of the logo to the size I wanted. Using LaserCAD’s tools, I assigned different functions to different parts of the design:
Cut – black lines
Speed Cut – blue lines
Engrave – red lines
These color codes help the machine distinguish between the different laser operations. Finally, I ran a simulation inside LaserCAD to make sure everything was working correctly and that the outcome would match my expectations before starting the actual cut.
Preparing the Material:
Placed the wood sheet on the laser cutting machine.
Used supports to keep the sheet stable and prevent movement.
Adjusting the Focus:
Set the laser focus to avoid noise and ensure precision.
Setting the Origin Point:
Clicked on "Box" to manually position the node at the desired starting point.
Selected "Origin" to lock the starting point for the laser cut.
Starting the Machine:
Clicked "Start" to begin the cutting and engraving process.
Retrieving the Final Part:
Opened the machine and removed the part after the cutting, speed cut, and engraving were complete.
Preparing the File:
Configured all printing parameters in Ultimaker Cura (e.g., infill density, support settings).
Exported the G-code file and uploaded it to an SD card.
Starting the Printer:
Inserted the SD card into the 3D printer.
Powered on the machine and selected the desired file.
Launching the Print:
Clicked "Start" to initiate the printing process.
Monitoring the Process:
Observed the printer’s performance to ensure smooth operation and quality output.
Challenge:
While making design changes and adding new curves to the glasses' face, our sketch became under-constrained, which led to instability and unpredictable geometry changes. This made further edits frustrating and error-prone. At first, it wasn’t obvious which parts of the sketch were lacking constraints, and the issue slowed down our progress.
Solution Applied:
To troubleshoot, I began moving parts of the sketch to see what shifted. This helped identify lines and curves without constraints. After pinpointing the problem areas, I used the "Fix" tool in Fusion 360 to lock key geometry in place temporarily. I also added the necessary dimensional and geometric constraints (like equal, tangent, and coincident) to make the sketch fully defined without over-restricting it.
Collaborative Insight:
I asked a peer and instructor for feedback, and they suggested avoiding overuse of the "Fix" tool because it can make future edits harder. Instead, they recommended using constraints strategically for more flexible but controlled sketches. Building on that advice, I refined the sketch using better constraint practices and only used fix this time in 3-4 lines because they were curves that can't be fully defined and they were so hard to be constrained this time.
Learning Outcome:
This challenge taught me the importance of systematically debugging sketches and the value of peer feedback. Fully constrained sketches not only reduce errors but are crucial for team-based projects where multiple people might edit the same file.
Challenge:
The original glasses design had a narrow support area between the eye sections and tight stud/nut placements, leading to weak structural integrity and poor fit.
Solution:
Following instructor feedback, I increased the support area for better stability and enlarged the stud and nut dimensions for improved fit and durability. These changes were applied to future iterations to support heavier loads.
Peer Collaboration:
I shared these improvements with peers and offered tips on strengthening designs. In return, their feedback helped me identify additional weak points.
Learning Outcome:
This experience reinforced the value of feedback and collaboration in refining designs for strength, usability, and durability.
Challenge Faced: Struggled with making fully defined sketches, especially during the laser-cutting phase of the robot bookmark design.
Initial Approach: Used simple or "primitive" tools in Fusion 360 to build the sketch, thinking it would save time quickly.
Issue Encountered: As the design progressed, the lack of constraints made the sketch unstable and difficult to export cleanly to LaserCAD.
Fabrication Problem: Unconstrained sketches can shift or behave unpredictably, leading to inaccurate laser cuts on the wood.
Advice to Others: Always design with the final fabrication in mind—this isn’t just a regular sketch; it’s something that will be exported and cut using LaserCAD. Taking the time to fully define your sketch early on ensures precision and avoids unexpected issues later when the design is implemented in the machine.
Solution: I focused on fully defining the key lines that directly affect the laser cutting process. By applying the necessary constraints and dimensions to these critical elements, I ensured the design remained stable and accurate during export to LaserCAD and during fabrication.
Fillet Application:
Applying fillets to object edges can reduce the need for supports and decrease 3D printing time.
Visualization Skills:
Using appearance settings in the design software to realistically visualize the final product before fabrication.
Inspiration from the Smile Box:
Incorporating smiley faces or positive designs on the box or gift to enhance user motivation and mental well-being.
I learned this week to give another person the keys to the car and trust their opinion.
We started off like, “Yep, we’re doomed,” but somehow—between Malak sculpting in 3D, Me laser-zapping parts, and Youssef steering the chaos—we actually made it! 🚗💨 Good vibes, great laughs, and zero meltdowns (almost).
Cute Robotic
First-Time Experience:
Engaged in a clay activity for the first time.
Creative Exploration:
Helped me tap into creativity and break free from the work-study routine.
Artistic Inspiration:
The final design reflected elements of Van Gogh’s style.
Personal Growth:
Improved my artistic skills and enjoyed the process of working with textures and colors.
Overcoming Challenges:
Initially faced confusion with the design but used colors to enhance the final piece.