Week 2 - Journal

So as many of you know, I wear glasses 👓 which makes this week's assignment feel very personal and exciting for me. Since the task is to design glasses, I felt like I was finally in my comfort zone. But of course, I didn't want to just make a standard, everyday pair… I wanted to design something fun, bold, and a little outside the box, but not too crazy 😅.

While browsing for inspiration, I came across some really creative 2D-shaped and letter-themed glasses. That instantly clicked with me! So I thought: why not create a pair of glasses that features the letters M and D; representing Maker Diploma? One letter on each lens, forming a quirky, lighthearted, and meaningful design that’s playful but still wearable.

It’s a fun way to reflect my maker identity and carry a bit of the diploma spirit right on my face 😄.

For preparing the files, I continued using Ultimaker Cura for 3D printing and LaserCAD for the laser cutter, just like last week.

As for the machines, I used the 3D printer (with PLA filament) to fabricate the arms of the glasses, and the laser cutter to cut the front frame (the part that holds the lenses) from 3mm plywood. The combination of these tools allowed me to explore both subtractive and additive manufacturing in a single project, which was really exciting!

After deciding on the design concept, I jumped into the design process using Fusion 360. I started with the laser-cut front part of the glasses—the frame that holds the lenses. I wanted to move away from my usual square-shaped glasses, so I went with a circular/elliptical design this time for a fresh look 👓.

Once I got the basic shape down, I added the letters M and D (for Maker Diploma) into the design—one on each lens area. After finishing the sketch, I used the 3D features in Fusion to extrude the shape slightly. Then I exported the sketch as a DXF file, opened it in LaserCAD, and set the cutting parameters. Since the entire design was just cuts (no engravings or vector etching), I only had to adjust the cutting speed and power before saving the final file.

Next, I worked on the arms of the glasses. I opened a new project in Fusion and started sketching based on the actual dimensions of my own glasses, which I measured using a caliper. I didn't have a clear idea at first, so I just played around with curves and circular features to give it a cooler, more unique style 😎.

After completing the sketch, I extruded it and added small fillets to smooth out the edges. I also made sure to include the mounting holes for assembly. Finally, I exported the model as an STL file for 3D printing.

Once the time finally came to fabricate my assignment, I headed to the lab with my wooden sheet in one hand and my laptop in the other. I started by uploading the designs to the machines, beginning with the 3D printer since it takes more time (the print was 55 minutes 😅). I uploaded the G-code file to the 3D printer via the TF card, selected my project, hit the start button, and let it cook on its own.

Then, I moved to the laser cutter. I opened the LaserCAD file I had prepared earlier, double-checked the parameters, and clamped the wooden sheet onto the machine’s table using 3mm brackets (since I was using a 3mm sheet). I turned on the machine and checked the focus. Once everything seemed okay, I went back to LaserCAD and downloaded the design to the machine.

Returning to the laser cutter, I reset the origin to a suitable starting point and hit the “Box” button to make sure the working area wouldn’t go beyond the sheet. After everything checked out, I closed the machine lid and hit the start button—then let it do its thing.

Once both machines finished, I grabbed the parts for the glasses and assembled them using M3 screws and nuts. Luckily, I had no issues with clearances or dimensions, and the assembly process went smoothly.

Later that day, I thought it would look even cooler with some color—so I let the creativity out of me 😂, and it actually turned out not bad!

Yes, I did ask for feedback during the end-of-week session, and it was really helpful. One important piece of advice the instructors shared was that 3D printers don’t always print with 100% dimensional accuracy. Specifically, when it comes to holes for screws, the final print might end up slightly tighter than designed. So, we were advised to make holes about 0.3 mm larger to ensure screws can fit properly in the final piece. That tip turned out to be super useful when I prepared my design for printing 🔧.

As for the laser cutting part, I discovered (through both trial and advice from others) that fully defining the sketch in Fusion 360 is essential. It not only avoids mistakes later but also makes exporting and implementing the design in LaserCAD much smoother and more predictable. That was a small but important lesson that I’ll definitely carry forward.

Another critical skill I learned is the importance of adding clearance in designs—especially for screw holes or interlocking parts. Small adjustments like increasing hole diameter by 0.3 mm can prevent parts from misfitting due to 3D printer tolerances or material swelling. This kind of foresight will be crucial for ensuring precision and functionality in the final build.

Overall, these lessons are helping me think not just like a designer, but also like a fabricator—planning for the real-world behavior of materials and machines.

One of the coolest things I learned this week was definitely the power of teamwork 💪. We were divided into two teams, with 3 members in each. In my team, I was the driver, and my teammates were Malak and Rania—Malak focused on designing the 3D part, while Rania handled the laser-cut part 🔧.

At first, we thought we were falling behind and wouldn’t finish everything on time. But by communicating well and trusting each other’s strengths, we actually pulled through and did a great job! It really showed me how much can be achieved when everyone works together toward a shared goal. Definitely a moment I won’t forget. 👏

This week was packed with awesome activities, but if I had to choose the coolest one, it would definitely be the extra sculpting session with instructor Mariem Salem 🎨. We worked with air clay, which was super fun and hands-on. What made it even cooler is that sculpting is actually a hobby I already enjoy—I’ve made some interesting pieces in the past, like a villain character inspired by a mix of different fictional characters (but mostly born from my own imagination 😈).

For this session, I kept with the villain theme and ended up sculpting... well, I’m not exactly sure what it is—but it looks like an evil, wicked cat 🐱👹. It was spontaneous, a little creepy, and totally fun to make. I’ll definitely never forget this creative and slightly chaotic little villain!