Week # 1- Journal

This week we were assigned to finish some self-study videos about laser cutting and 3d printing and how to install their two desktop applications (Cura & RDWorks).

After finishing the videos, I visited 3axis.co to pick a design and download it as a (.DXF) file so we implement it on the laser cutting machine in my lab.

I chose this Do not disturb sign since I really need it in my house (iykyk😮‍💨)

I should be laser-cutting this part later this week after taking my instructors opinion on it, stay tuned for the photo! 👀

As for the 3d printing model, after searching for almost half an hour on Thingiverse; I came up with this Thor's hammer keychain file and downloaded it.

As before, stay tuned for the final photo once I make sure it's ready to be printed!

For 3D printing:

Software used --> UltiMaker Cura V5.10.1

Material used --> coloured PLA 

Machine(s) used --> Prusa MK3 3D Printer || Prusa MK3 S Plus 3D Printer 

For Laser cutting:

Software used --> RDWorksV8

Material used --> 3mm thick Plywood sheet

Machine used --> El Malky ML149 Laser Cutter 

3D Printing preparation:

After uploading the .STL file into Cura, I started editing the parameters to meet my 90 min duration constrain, these are my final parameters:

• Infill density of 20%

• 120% up-scale

• Standard layer thickness 0.2 mm (Fine texture)

The total time turned out to be 1hr 22mins, with a mass of 12 grams

Laser Cutting/Scanning preparation:

I downloaded two .dxf files (one for the cut and one for the scanned drawing), and imported them into RDWorks to start editing it, here are my final parameters:

[Cutting]

• speed of 40 mm/s

• power of 45%

[Scanning]

• speed of 300 mm/s

• power of 30%

When I went to the lab with my Flash drive, first thing I re-opened the File on Cura to make sure that my parameters are correct, then I uploaded my gcode on the printer's SD card.

3D Printing steps:

• Clean the magnetic bed by alcohol to ensure surface cleanliness

• Add the desired filler material/colour 

• Choose your file from the SD card after inserting it

• The machine will start calibrating the position and start printing

• Make sure to see the first couple of layers to catch any problems early on and minimize waste

As for the laser cutting, I opened my files on the software to check the parameters and the dimensions of my design, then I downloaded it to the machine's software, following some steps:

• select your file by pressing "file" button

• Place your wooden sheet and fix it on the bed, check the focus and position the nozzle to one of the corners

• Press on the "origin" button to set this position as initial.

• Press on the "Frame" button to make sure your cut is within the sheet limit, then start the machine after closing the door.

All in all, it was pretty good for my first time using these machines, here are my final results as promised! 🤩

Stay tuned for my upcoming ones, because the next time it is going to be my own design not just from an external library 😜

A small problem I faced was in marking the letters with empty spaces inside such as "B" or "D", when I choose a colour and select the outline it marks the whole letter with that colour.

After couple of trials turns out i just needed to mark the inner circle after marking the outer one to remove the filled colour 😃.

This week we learned two essential skills (laser-cutting & 3D printing); which are considered the core of my final project:

• Laser cut the body layers

• 3D-print the balls, obstacles and maybe other items for design!

I even took a little insight about how dimensions turn out to be and how sometimes the prints could be better off without supports!