Week 1 - Journal

This week’s assignment feels really special to me because it combines two ideas that are close to my heart.

For the laser-cutting project, I’m creating a clock featuring the map of Palestine. This isn’t just a design for me it’s a reflection of my deep sense of belonging & connection to Palestine. 

The map is a powerful symbol of identity, history and resilience. Every detail in this design carries meaning and I want the clock to represent the enduring presence of Palestine in both time and our hearts.

For this assignment, I used specific machines, software and materials that best suited the requirements and the vision for my projects.

For the laser-cutting project:

• Machine: I used the Malky Laser Cutter ML64, which is highly precise and reliable for detailed designs like the map of Palestine. It allows me to achieve clean and accurate cuts for the intricate map details and the overall clock design.

• Software: I worked with LaserCAD v8.21.10.3 to prepare the design and optimize it for the laser cutter. The software’s features made it easy to translate my design ideas into a format the machine could execute perfectly.

• Material: I chose a wooden sheet for its natural and timeless aesthetic. Wood adds warmth to the design and feels connected to tradition, which aligns perfectly with the cultural significance of the map of Palestine.

For the 3D printing project:

• Machine: I used the Creality Ender-3 V2, a versatile 3D printer that’s great for creating detailed models like the Volkswagen Beetle. Its reliability and precision helped me capture the car’s classic curves and unique shape.

• Software: I prepared the 3D model using Ultimaker Cura. The software’s slicing capabilities ensured that the design was optimized for printing, with smooth layers and minimal errors.

• Material: I used PLA filament because it’s easy to work with, eco-friendly and produces a smooth finish that’s perfect for a detailed model like the Beetle.

I completed two exciting assignments: manufacturing a 3D beetle car using 3D printer & a Palestine map wall clock using laser cutter.

1. 3D Beetle Car:

   • Design Preparation:
     I used UltiMaker Cura software to process a ready-made 3D model of a beetle car. The parameters were set as follows:

Support Structure: Tree support was added with placement set to "Touching Buildplate" for optimal support & ease of removal.

1. • Printing Process:
     After completing the setup, I exported the model as a G-code file & sent it to the 3D printer specialist via Slack. The specialist checked the file, copied it to a memory device & then loaded it onto the 3D printer. Once everything was set, we started the printing process, which took 1 hour & 27 minutes to complete. After printing, I cleaned the model by removing the brim & support structures.

2. Palestine Map Wall Clock:

   • Design Preparation:
     I used a ready-made vector design for a Palestine map wall clock in LaserCAD software & exported it as a DXF file.

   • Cutting Process:
     I sent the DXF file to the laser-cutting specialist for verification. After checking the file, the specialist downloaded it onto the laser-cut machine using a USB cable connected between his lap top & the laser cut machine. I placed a wood sheet on the cutting bed & secured it with two locks to prevent sliding. Then, I pressed the "Origin" button to set the starting position & used the "Box" button to verify the cutting area. After ensuring the setup was correct, I closed the machine’s cover & pressed "Start." The cutting process took 1 minute & 18 seconds to complete.

For the laser cut assignment, I asked Mohanad for advice on how to edit my design to ensure some lines would be cut & others scanned. The issue was that the design had many connected & unseparated lines, so when I selected a single line for speed cutting, multiple lines were selected together. Addressing this problem, he advised me to look for a better design instead. However, instead of searching for a new design, a friend helped me resolve the issue by adjusting the existing design.

For the 3D model, Yassin provided helpful feedback during his evaluation. He pointed out that the model would require supports and noted that the open windows on the car wouldn’t work well for such a small-scale model. Taking his advice, I found a new design with closed doors & showed it to him. He confirmed that this choice was much better

One of the first challenges I faced was the feedback from Mahmoud Walid, the 3D printer specialist. When he saw my 3D model of the beetle car, he expressed disappointment, explaining that the design wasn’t even 3D printable in its current form. He mentioned that it would require many supports, which could affect the final appearance & make it look far from a proper car. This feedback was disappointing & I expected the printed model to fall short of my expectations. However, Elhamdulillah, the final result turned out much better than I anticipated—the model looked good & was acceptable, despite taking into consideration the earlier concerns.

For the laser cut assignment, I encountered a challenge with the dimensions of my model. I had designed it to be a functional wall clock for my home, but scaling it to a realistic size required more material than anticipated. During the cutting time, the program coordinator informed me that I should not use an entire sheet of wood for a single assignment because only six sheets were allocated for the entire program. This was frustrating because I had not been informed earlier or given a specific quota for this assignment. In contrast, the 3D printing assignment had a clear limit of 90 mins, which was helpful for planning. With time running out & to avoid material shortages for future projects, I decided to adapt & scale down my design to one-third of the original size. This compromise allowed me to complete the assignment while conserving materials.

Some mistakes or challenges others can avoid include:

1. Ensuring that 3D models are designed to be printable with minimal supports to avoid compromising quality.

2. Seeking clarity about material quotas or restrictions for assignments ahead of time to prevent last-minute surprises.

3. Being flexible and open to feedback to adapt to unexpected constraints without compromising the project's overall quality.

For instance, I learned how to refine designs for laser cutting, ensuring that lines are appropriately separated for cutting, engraving or scanning. This understanding will help me create precise &functional components for my final project while optimizing material usage.

Additionally, the challenges I faced with 3D printing taught me the importance of designing models that are both printable & visually appealing. I now know how to evaluate designs for feasibility, minimize supports & choose models that align with the scale & functionality required.

These experiences also enhanced my problem-solving & adaptability. I learned how to make quick decisions, like scaling down designs, to meet material constraints without compromising the design itself or the quality. This will be especially helpful when managing the resources allocated for the final project.

Overall, these skills will enable me to approach my final project with better planning & precision, ensuring a successful & efficient outcome.

The coolest thing I learned this week was how to adapt & optimize designs for laser cutting & 3D printing. Understanding how to adjust line settings for cutting, engraving & scanning was fascinating, as it showed how small tweaks can drastically impact the outcome. Similarly, learning about the importance of designing 3D models with minimal supports & ensuring their printability was eye-opening.

One moment I will never forget was seeing my 3D beetle car model after printing. Despite the initial feedback that it might not turn out well, but elhamdulillah it exceeded my expectations & looked better than I had hoped. That experience taught me the value of perseverance & trusting the process, even when things seem uncertain.