Week 2 - The Glasses 🥸

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)

The objective of week #2 was to design, manufacture and assemble glasses where

The frames are 2.5D.
The arms are 3D printed.

I got inspiration from Google as seen in the pics.

Tool Chain

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

I used Autodesk Fusion to design the frames and the arms of the glasses..

Then, I used RDWorks V8 to prepare the 2D parts for the laser cutter and set the cutting and engraving parameters. The part was then cut using the laser cutter. Also, I used Cura for slicing and preparation of the 3D part. Settings were adjusted for the Pursa 3D Printer.

For the materials, I used 3mm Ply Wood for laser cutting and PLA Filament for 3D Printing.

I used Fusion to design the components.

I used Prusa 3D Printer for the 3D parts and the laser cutter for the 2D parts.

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?

The designing process of the arms

1. I took realistic dimensions of the arms.
2. I designed the body of the arms on Fusion according to the following dimensions and made sure that the entire design is fully defined.

3. I extruded the part 5 mm to give it strength when printed.

4. On the top of the new plane, I sketched the perpendicular side of the arms that would be connected to the frame and extruded it to 9 mm to match the frame design.

5. On that side, I draw a 3mm diameter circle and applied an extruded cut to leave a space for the screw joint.

6. Apply a 2.00 mm fillet to the corners of the arms.

7. Import the file to Cura and adjust the parameters. I found a problem with the dimensions. Hence, I upscaled the design to 1000% to match the actual size of the arms.

Infill = 5.0% | Profile Extra Coarse 0.6 mm

8. Finally, I exported the .gcode

The designing process of the frame

1. I took realistic dimensions of the frame.
2. I designed the frame on Fusion according to the following dimensions and made sure that the entire design is fully defined.

3. I extruded the part to 3mm (2.5D)

4. I saved the DXF file.
5. I imported the file in RDWorks V8 to prepare it for laser cutting.
6. I set all the sketches to cutting parameters: speed and power.

Download The Arms .gcode

Download The Arms .stl

Download The Frame .dxf

Download The Frame .stl

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?

For laser cutting, the process went as follows:

I opened the .ai file on the PC.
I reviewed all parameters to make sure they match the correct values set by the instructors.
I turned on the laser cutting machine and the Fume Extractor.
I downloaded the design.
Then, I adjusted the origin of the nozzle and framed the design to assure the dimensions are fitting into the board.
I started the cutting process.

For 3D printing, the process went as follows:

The lab specialist went through the file and the exported .gcode
My design was not set for Pursa machine. Hence, the lab specialist advised to adjust this parameter.
I added the .gcode to the sim card.
Then, I chose the filament of my color choice.
I cut the filament diagonally and then loaded it to the machine.
I started the 3D printing process.
The machine took some time to heat the bed. Then, it started the 3D printing process.

The process ✍️

The components 🦾

The product 😎

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?

While preparing the arms of the glasses for 3D printing, I forgot to design two inverted versions since the two arms should be mirrored.

The lab specialist advised me to mirror the design so that it matches the reality and could be assembled easily with the frame.

I learnt how important it is to have a cardboard model of your design before excution.

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