Week 1 - Journal

This week’s assignment involves preparing design files and fabricating models of our choice using 3D printing and laser cutting. As a devoted Potterhead, I chose to 3D print a model of Harry Potter, the iconic protagonist of the beloved wizarding series. Harry’s journey of courage, friendship, and self-discovery continues to inspire us, making him a perfect choice for this project.

For the laser cutting task, I selected the "BELIEVE" sign from Ted Lasso, a comedy-drama about an American football coach hired to manage an English football team, despite having no experience. Through his kindness and positivity, Ted transforms the lives of his team, highlighting the importance of belief and connection. The "BELIEVE" sign, created by Ted to inspire the AFC Richmond players, symbolises hope and self-confidence. Though initially met with scepticism, it becomes a unifying emblem and perfectly encapsulates Ted’s philosophy: true success lies in the journey and the bonds we create, rather than just the outcome.

"For me, success is not about the wins and losses. It's about helping these young fellas be the best versions of themselves, on and off the field."

Ted Lasso.

1. 3D Printing

Software I used UltiMaker Cura to handle the 3D printing task. This open-source software takes 3D models (like STL files) and converts them into G-code, the language the printer understands. 

Machines & Materials "Creality Ender 3 V2 3D Printer" which is versatile and can use a variety of materials but we made use of PLA (Polylactic Acid) as it's easy to print, biodegradable, less prone to warping. 

• For the 3D printing task, I found a 3D printable model of Harry Potter on an open-source library for 3D models Thingiverse (https://www.thingiverse.com/thing:3200840).

 After downloading the STL file, I opened it in UltiMaker Cura and adjusted key parameters as:

• Orientation: Positioned the model to minimize overhangs and achieve a smooth finish.

• Support: Added supports to provide stability during printing (support type: tree)

• Layer Height: Set to achieve a balance between detail and printing time. (Resolution of 0.2mm)

• Infill: Chosen to provide enough strength without wasting material. (10% and of type Cubic)

• Brim: Added to improve adhesion and prevent warping during the print.

to ensure the print was optimised. Once everything was set, I sliced the design to check that the print time stayed within the allowed limit, then saved it as 3MF file and a G-code file ready for the printer.

• For the laser cutting task, I started with a JPEG image, which I converted to a DXF file using Convertio since LaserCAD only works with that format. In LaserCAD, I set the dimensions to match the sheet size (30 cm × 50 cm) and used three colours to define the operations: Black for cutting, Red for scanning, and Blue for speed cutting. Before exporting the file, I fine-tuned settings like mode, speed, and power to achieve the desired result, then saved it as a DXF file.

3D Printing Process

• 3D Printer Setup:

  • The design was printed using a Creality 3D printer with PLA filament, chosen for its ease of use and good surface finish. The G-code file was transferred to the 3D printer via a memory card and its reader.

  • The printer bed was leveled, and the filament was loaded before starting the print.

• Monitoring the Print:

  • The print process was monitored to ensure there were no errors like layer shifting or filament clogging.

  • The print time was approximately 66 minutes, during which the printer laid down layer after layer to build the Harry Potter's model.

4. Post-Processing

• Support Removal: After printing, the support structures were carefully removed using a plier.

My challenge was with the laser cutting task, I wanted to work on the "BELIEVE" sign from Ted Lasso and I couldn't find the sign ready-made file in a DXF format. While I could have converted a JPEG file to DXF using a converter, my lazy streak kicked in, and I spent way too much time scouring the internet for a ready-made DXF version instead. Eventually, with the help of a friend of mine "Menna Bissar", she came up with the idea of making use of Convertio https://convertio.co/ and the whole process took like couple of minutes to finish preparing the file for printing, This teaches us that you should not always be choosing a lazy person to do a hard job. However,

  “Laziness is the mother of all bad habits, but ultimately she is a mother, and we should respect her.” – Unknown 

My final project "TICO" will involve various components that can benefit from 3D printing and laser cutting to ensure precision and functionality. 

3D Printing:

1. Customised Parts: TICO’s mechanical structure, like the robotic arm or holder, will require small, detailed parts that are lightweight and sturdy. 3D printing allows you to create these components with precision.

2. Aesthetic Enhancements: You can use 3D printing to make decorative or thematic additions, such as a case for the robot.

Laser Cutting:

1. Base and Platform: Laser cutting is ideal for creating TICO’s base

I was absolutely happy to see my first creation come out of the laser cutting machine—it felt like magic watching a simple design transform into a tangible product! The precision and sharpness of the cuts were beyond satisfying, and it gave me a real sense of accomplishment. 

From working with the 3D printer, I learned the importance of patience and attention to detail. Manipulating the design taught me how small changes in parameters like infill and layer height can drastically affect the final output. Slicing the design was an eye-opener—it showed how critical it is to optimise the print for time and quality. Overall, both experiences made me appreciate the balance of creativity and technical skill that goes into turning ideas into reality.

This week has been full of new experiences and valuable lessons!.

On top of that, I absolutely loved the party ideas we brainstormed in the A1/A2 groups during the lecture. They were so creative and fun—it was such a great way to bond and share ideas. The Wednesday session was another highlight; hearing everyone’s contributions was genuinely inspiring. Each one brought fresh perspectives, and it sparked so many thoughts for me moving forward.

What stood out most this week was the opportunity to work with completely new people during every on-site session. It was refreshing and challenging in the best way, and I loved how we managed to create a sense of harmony and teamwork in such a short time.