Week  2- Journal

Laser Cutting for Glasses Frame:

• Software Used: RD Works 

• Machine Used: A laser cutter 

• Materials Used:

  • 3mm Wooden Sheets

  • 3M screw and nuts for assembling frame with arm.

3D Printing for the 2 arms:

• Software Used: Fusion 360,Cura

• Machine Used: A 3D printer (Prusa i3 Mk3/Mk3s) 

• Materials Used:

  • PLA Filament: Black PLA 

For the 2.5D frame:

The 2.5D model I created in Fusion 360 started with a simple circle. I used the offset tool to create a larger circle around it, forming the outer frame. To connect the smaller and larger circles, I drew lines on each side to close it as a half-circle. Inside, I added a zigzag pattern using the line tool, offset it, and connected the angles with additional lines and offsets. After trimming unnecessary parts, I mirrored the design for symmetry and connected the two mirrored parts with a curved line.

Next, I added a small circle for the screw and nut, mirrored it, and ensured everything was fully defined. Once the sketch was complete, I pressed 'Finish Sketch,' extruded the design to 3mm, and applied a wood appearance to the model. And, of course, I saved the file—rule number one!

For the 3D arms:
For the glasses arm, I used Fusion 360 to create the design based on the dimensions provided in the uploaded illustration. I started by creating a new sketch and saved the file as "glasses arm." I began drawing a rectangle from the origin point, ensuring it was fully defined. Next, I added a curve at one end, offset it, and connected the two curves with a smaller curve. I trimmed one side of the rectangle to shape the arm, making sure all parts were fully defined.

Once the sketch was complete, I finished it and extruded the arm to 10mm. On the top side of the arm, I drew a new sketch for the screw and nut hole. I created a fully defined rectangle, extruded it, and then added a 3.2mm hole for the screw and nut. Afterward, I used the fillet option to smooth the edges for a cleaner look. Finally, I saved the design as a mesh in STL format, ready to upload to Cura and print. I changed also the appearance using plastic black color.

 Here are the files in the  dxf and stl

Laser Cutting for the Frame (2.5D Model): Press Here please to enjoy the video.
The DXF file of the frame was properly prepared in RDWorks, with the power set to 45 and the speed set to 40 for cutting. the wooden sheet (3 mm thick) was fixed to the laser cutting bed using clips. I choose my file after downloading it so that's mean it's ready in the laser machine now . After confirming the origin and frame, The vacuum system was turned on, and the cutting process began, taking just 2 minutes. Once complete, I opened the machine, removed the clips and closed the vacuum.

3D Printing for the Arms (3D Model): Press Here to enjoy the video.

The STL file for the arms was sliced using Cura. I adjusted the orientation to eliminate the need for supports, with the layer height set to 0.2 mm. The estimated print time was 1 hour and 49 minutes, consuming 20 grams of red PLA filament. The sliced file was exported as G-code and transferred to the 3D printer using an SD card. The printer successfully fabricated the arms within the specified time and material limits.

During the project, I asked my instructors and a specialist for feedback on a few aspects of the design and assembly. I sought advice on resizing the frame to fit better, and they suggested adjusting the measurements slightly to ensure a more comfortable and functional fit. The specialist also helped me troubleshoot the issue with the mirrored arms, advising that I should use the software’s mirroring function to correct the alignment.

Challenges:

While working on the project, I encountered a few challenges. The first issue was with the wooden sheet for the glasses frame—it was initially too large for a normal human size. To solve this, I resized the frame using the design software to ensure it would fit properly.

The second challenge occurred when I duplicated the arm model. I realized that I needed to mirror one of the arms so that both would fit on the same side of the frame. This adjustment was necessary to ensure the arms would function symmetrically.

Additionally, I had to make sure there was enough space between the frame and the arms for the nuts to fit properly. Initially, I didn't leave enough room, but after some trial and error, I adjusted the design to ensure the nuts could be inserted without difficulty.

Solutions:

To solve these problems, I relied on trial and error for resizing and adjusting the components. I also consulted with a peer, who gave me advice on how to mirror the arms correctly. The distance issue was resolved by modifying the frame design to allow for enough space for the nuts.

Additional Resources:

I didn’t use a specific tutorial for these challenges,it was enough for me the tutorials in Maker diploma website.

This week, I’ve learned how to adjust designs for precision, troubleshoot issues through trial and error, and use feedback to improve my work. For my final project, I’ll apply these skills by refining my design, ensuring proper alignment, optimizing material use, and seeking feedback at key stages. This will help me create a more functional and polished final project. 

The coolest thing I learned this week was how to integrate both laser cutting and 3D printing techniques to create a functional and stylish product. I’ll never forget how making small adjustments, like resizing and mirroring parts, can completely transform the outcome of a project and how feedback from peers and instructors can make a huge difference in improving designs .

My colleague painted the wooden part of the bookmark to make it look more feminine.