week 2

Ideation

The idea came from this sunglasses.

Tool Chain

Softwares:

UltiMaker Cura for 3D printing

RDWorksV8 for laser cut.

fusion 360

The Material

PLA

Plywood 3mm

The Machines

PRUSA i3 MK2 3D Printer

El Malky ML149 CO2 Laser Cutter

Design/Preparation Process

Front Face of the Glasses

The design of the front face is fully definedd

Open Fusion 360 and create a new design file.
Save my project with a name.
Create a 2D Sketch
Select the Front Plane.
Use the Rectangle Tool to create a rectangle for the lens area.

Lens width: 52 mm (per lens).
Lens height: 37 mm.
Draw a bridge area between the lenses:
Bridge width: 17 mm
use the fillet tool on the edges of the lenses and make the radius 5 mm
Add Rim Holes for Screws
Use the Circle Tool (C) to create a 3.3 mm diameter hole near the outer rim of each lens.
Place the holes approximately 5 mm away from the lens edges.
add Polygon: radius = 5 mm
Customize the Design
Apply materials: Go to Appearance (A) and choose wood.

formatsave the front face design as ( dxf) format

The sidearm of the glasses

The design of the side arm is is fully defined.

1. Create a New Component

Create > New Component and name it "Side Arm.".

2. Create a Sketch for the Arm

Select the Right Plane (YZ Plane).
Use the Line Tool (L) and draw L shape
use the fillet tool on the edges of the L-shape raduis is 40mm and 50mm and at the end of the side 2.5mm
- Horizontal section: 140 mm (length of the side arm).
- Vertical section (L-extension): 10 mm

3. Extrude the Arm

Use the Extrude Tool (E) to extrude the arm to 4 mm thickness.

the L-shaped extension to the arms

I put the 3d design in the front plan and did a new sketch and then draw a rectangle with dimensions 10*10

extrude the L-shaped

after drawing, finish the sketch and then extruted thE L shape

hole for attachment with the front face using M3 screws

use the new sketch and draw a circle with 3.3mm for the M3 screw

extruded cut from 2 sides direction about 5mm

use feature fillet and make it 2mm

copy and mirror the 3D design

I do copy for the design, and then after that, I do mirror for the copy to make it 2 sidearm.

I remove the copy body and then

Customize the Design

Apply materials: Go to Appearance (A) and choose PLA

save the design in STL format

1- Click right on the body 1 . do the same at body 3

2- save as mesh

then save it in the file

Development/Implementation Process

The Laser Cut

I import the DXF file in RDWorks , and set up the speeds and powers. to be

power: 45 / speed : 40

VID_20250109_135638.mp4

After downloading, the design file is in the laser cutting machine. I went to the control box in the laser machine.

I selected my design file from the machine's memory, and I had to set the machine's starting origin and click "Frame" to ensure that no design elements were missing from the plywood sheet.

and then test the laser pulse

The 3D Printing

export the STL files. and then move the arm away from the other arm

then do flat to the design on the bed

I set up the printer.

VID_20250109_144621.mp4

The lab specialist reviewed the design in Ultimaker Cura to see if the printer settings and design scale were suitable.

We moved the design to SD card and then I entered the card into the printer and I selected my design and then the printer started working

after the end printing

Overcoming Challenges:

The problem that I faced was: that when cut by laser, I did not set up the focus of the laser so the design was not cut correctly

the fab lab specialist told me to set the focus of the laser and cut another design

Assignment Design Files:

front face DXF

side arm stl

Page updated

Report abuse