Embedded Files
Monday
Description:
Today was the first day back from spring break, and we spent the class period getting reoriented with our project and troubleshooting the circuit. Since we had been away from it for a while, our first task was to carefully review where we left off and try to understand why the circuit was not functioning properly. We tested different possibilities and checked our connections, but we still ran into issues getting it to run consistently.
To help us move forward, we decided to speak with Mr. Rojas about the problem. After explaining what we had tried so far, he suggested that the issue might be related to our power source and recommended using a different adapter. After considering his advice and discussing it as a group, we ultimately decided that the most reliable option would be to try running the circuit off of a school desktop computer to ensure a stable power supply. This helped us narrow down our approach and gave us a clearer direction for solving the issue moving forward.
After addressing the circuit, we shifted our focus to beginning the physical construction of our model. We wanted to start cutting out the block pieces that will make up our final structure. To prepare for this, we first took a large sheet of acrylic and carefully measured it so it could be resized to fit into the laser cutter. Accuracy was important during this step because the material needed to be properly sized in order for the laser cutter to work effectively and produce clean cuts.
Once we finished measuring and marking the acrylic, we used the table saw to cut the sheet down into the correct dimensions. We worked carefully to ensure straight, even cuts so the pieces would be ready for the next stage of fabrication. Although we did not complete all of the cutting today, we made solid progress by preparing the material and beginning the early stages of shaping our model components.
Design Process Step:
This work fits into the testing and prototyping stage of the design process because we are actively working through problems with our circuit and beginning to build and prepare the physical components of our final model. During this stage, we are not just planning or designing on paper—we are testing real materials, troubleshooting issues, and making decisions based on how our system behaves in real conditions.
The circuit troubleshooting shows the testing aspect of the process. We identified that our original setup was not working properly, then evaluated possible causes, tested different ideas, and sought feedback from Mr. Rojas. Based on his suggestion, we adjusted our approach by considering a different power source, which is an example of refining our design through problem-solving and iteration.
At the same time, we began the prototyping/building phase by preparing the acrylic pieces for our model. This included measuring, marking, and cutting the material to the correct size so it could be used in the laser cutter. These steps are part of physically constructing the prototype and turning our design into real, usable components.
Overall, this stage of the design process is important because it combines troubleshooting, experimentation, and hands-on building. It helps us identify issues early, improve our design decisions, and move closer to a functional final product.
Tuesday
IMG_2682.MOVDescription:
Today, we used the acrylic pieces that we had cut the previous day to begin cutting out the specific shapes needed for our block components. This step marked an important transition from preparing raw material to actually producing the precise parts required for our final model. We imported our design file from Fusion into the Glowforge software, which allowed us to directly translate our digital design into a physical cut. This helped ensure accuracy, since the machine follows the exact measurements and shapes from our file.
Once the file was uploaded, we carefully aligned the acrylic sheet in the Glowforge to make sure it was positioned correctly before starting the cutting process. We were able to successfully cut out three full copies of the design, since our plan was to double-layer certain parts of the block for added strength and stability. Each pass required careful monitoring to make sure the cuts were clean and fully separated.
However, when we moved on to the fourth copy, we encountered an issue. Even after attempting multiple passes with the Glowforge, the machine was unable to cut all the way through the acrylic. We adjusted settings and tried again, but the material still did not fully separate, which slowed our progress. Because of this, we were unable to complete all of our planned cuts within the class period.
By the end of the session, we ran out of time, but we documented where we left off and planned to continue troubleshooting and retrying the remaining cuts during the next class. This step was an important part of refining our fabrication process and learning how material thickness and machine settings can affect production.
Design Process Step:
This step is considered prototyping because we are actively turning our digital design into a physical model by cutting precise acrylic components using the Glowforge. By importing our Fusion design file into the machine, we are directly translating a digital prototype into real-world parts. This is a key part of prototyping because it moves the project from planning and modeling into physical construction.
It also includes elements of testing and iteration because we are not simply producing final parts on the first try—we are monitoring how the machine performs, adjusting settings when needed, and responding to issues that come up during production. For example, when the fourth copy did not cut all the way through, we had to reassess the process and recognize that adjustments would be needed in future attempts. This kind of troubleshooting is an important part of refining a design and improving the fabrication process.
Additionally, careful alignment of the material, repeated passes, and ensuring clean cuts all show that we are evaluating the effectiveness of our methods in real time. By documenting problems and planning to continue in the next class, we are engaging in iteration, which is when a design is continuously improved based on testing results.
Overall, this stage represents the shift from designing to building, while also emphasizing learning from errors and improving the process as we move closer to a final working product.
Wednesday
Description:
After running into some issues the previous day, Mr. Rojas checked the Glowforge machine and determined that it needed to be cleaned in order to function properly. This likely explained some of the inconsistencies we were seeing with the cuts. After the cleaning, we attempted to run the file again, but we still noticed that the acrylic was coming out charred and slightly burnt instead of cutting cleanly through. This indicated that there were still issues with either the machine settings or the material being used.
To help improve the results, Mr. Rojas provided us with a higher-quality type of acrylic. This new material made a noticeable difference in the cutting process—it was more durable and allowed the laser cutter to cut through more cleanly and efficiently. Because of its improved strength and consistency, we also realized that we no longer needed to double-layer the pieces, which simplified our design and saved time in the long run.
During this process, Yohanna worked closely with Mr. Rojas to test and adjust the cutting setup using the new acrylic, ensuring that the machine settings were properly aligned for the improved material. At the same time, Wynnie focused on post-processing the previously cut block base pieces. She used Goo Gone to remove leftover tape residue from the acrylic surfaces. She carefully sprayed it onto the cut-out pieces, allowed it to sit for a short period so it could break down the adhesive, and then wiped it off using paper towels. Afterward, she washed the pieces with soap and water to ensure that any remaining residue was fully removed, leaving the parts clean and ready for assembly.
Overall, this class period involved both troubleshooting the laser cutting process and refining our materials, as well as cleaning and preparing previously cut components to move closer to final assembly.
Design Process Step:
This stage of the design process focuses on testing how our design performs in real conditions, identifying problems, and making improvements before final assembly. During this class period, we continued working with the Glowforge laser cutter and refined both our materials and our process based on issues we encountered in previous attempts.
After earlier difficulties with burning and inconsistent cuts, Mr. Rojas inspected the machine and determined that it needed to be cleaned. This step was important because machine maintenance directly affects the quality and accuracy of our cuts. Even after the cleaning, we still noticed some charring, which showed us that we needed to further adjust our approach. To improve the results, we switched to a higher-quality acrylic provided by Mr. Rojas. This material produced significantly better results, cutting more cleanly and consistently. It also improved the structural strength of our pieces, allowing us to simplify our design by eliminating the need for double layering.
While part of the team focused on improving the cutting process with Mr. Rojas, other members worked on refining previously completed components. Wynnie focused on cleaning the acrylic block base pieces by removing tape residue using Goo Gone. She applied the solution, allowed it to break down the adhesive, and then carefully wiped it away with paper towels. After that, she washed the pieces with soap and water to ensure they were fully clean and ready for assembly.
Overall, this stage of the project involved troubleshooting technical issues, improving material quality, and refining components through cleaning and preparation. It helped us move closer to a more functional and polished final prototype.
Thursday
Description:
Today, we focused on preparing our block base so it could be properly bent in the next stage of construction. This step was important because the accuracy of the bend depends heavily on how precisely we mark and measure the material beforehand.
To begin, I logged into Fusion to locate the exact dimensions and reference points needed for the bend in our design. Since our model includes curved and non-linear geometry, it was somewhat challenging to identify the correct section where the bend should occur. I had to carefully inspect the model from different angles and cross-check measurements to ensure I was selecting the correct location that matched our physical build plan. After spending some time reviewing the design, I was finally able to determine the correct spot for the bend.
Once I identified the proper location, I used a ruler to transfer that measurement onto the actual acrylic piece. I carefully drew a straight, even guideline directly onto the material to act as a reference for bending. This step was crucial because even a small misalignment could affect how the final structure fits together. I made sure the line was as precise as possible so it would accurately reflect the design from Fusion and provide a clear guide for the heating and bending process later on.
Overall, this step helped bridge the digital design with the physical fabrication process, ensuring that our block base is properly marked and ready for the next stage of bending and assembly.
Design Process Step:
This stage involves taking the digital design and turning it into a physically accurate plan that can be built and tested. In our work, we are not just designing in Fusion anymore—we are actively translating that digital model into real-world measurements on the acrylic. By identifying the correct bend location in Fusion and then carefully transferring that information onto the material, we are refining the design so it can be physically constructed with accuracy.
It also falls into prototyping because we are preparing the actual material for fabrication. Drawing the bend line on the acrylic is a critical step that directly affects how the final structure will form. Since curved or complex geometry made it more difficult to find the exact bend point, we had to analyze the model carefully and adjust our understanding of how the digital design translates into a physical object. This kind of problem-solving and adjustment is a key part of prototyping, where small decisions impact the success of the final build.
Overall, this stage is important because it connects the digital model to real-world construction, ensuring that the design is accurately prepared before cutting, bending, and final assembly.
Friday
Description:
After accurately measuring and marking the bend line on the block base, we moved on to the next stage of physically forming the material. We carefully positioned the acrylic into the metal bender, making sure it was aligned with the marked line so the bend would occur in the correct location. This step required precision, since even slight misalignment could affect the final shape of the base.
To help make the acrylic more flexible and reduce the risk of cracking, we used a heat gun to evenly warm the material along the bend line. The goal was to soften the acrylic just enough so it could hold a clean, stable bend once pressure was applied. We took our time heating the surface to try to ensure consistent flexibility across the entire section.
However, as we began applying pressure with the metal bender, we ran into significant issues. The acrylic did not seem to be bending as expected, even with continued heating. In addition, the bending machine itself began to lift slightly off the ground when force was applied, which made it difficult to maintain steady pressure and control over the process. This instability affected our ability to complete a proper bend.
We continued attempting to adjust our technique throughout the class period, trying different amounts of heat and repositioning the material, but we were ultimately unsuccessful in achieving the desired bend. By the end of the period, we had not yet been able to complete this step, so we documented the issue and planned to revisit the process in the next class with adjustments to improve stability and heating consistency.
Design Process Step:
This stage involves taking our design from planning and preparation into real-world application by physically testing how our materials and construction methods work. In our case, we had already measured and marked the bend line on the block base, which was part of preparing the design for fabrication. Once that was complete, we moved into actually attempting to form the material, which is a key part of prototyping.
When we placed the acrylic into the metal bender and used the heat gun to warm it, we were testing how our design responds under real conditions. This is important because it allows us to see whether our planned approach will actually work as expected or if adjustments are needed. During this process, we observed that the acrylic was not bending properly and that the machine was lifting when pressure was applied, which revealed issues with both material behavior and setup stability.
Even though we were not successful in completing the bend during this attempt, this is still a valuable part of the design process. Testing and prototyping includes trial and error, and our experience helps us identify what needs to be improved for the next iteration. By recognizing these problems, we can adjust our technique, improve stability, and refine our approach moving forward to achieve a better final result.
Plan Moving Forward:
As we move forward into next week, our main focus will be continuing the fabrication and assembly stages of our project by refining both the physical structure and the electronic components. One of our top priorities will be completing the bending process for all remaining acrylic parts so that they match the correct angles and dimensions needed for proper assembly. This step is important because accurate bends are essential for ensuring that all the pieces fit together correctly and that the final structure is stable and aligned with our original design.
In addition to finishing the bending process, we will also begin assembling the individual components into a complete structure. This will involve carefully joining the bent pieces together, checking for fit and alignment, and making any necessary adjustments to ensure everything connects smoothly. We may also need to reinforce certain areas to improve strength and durability, especially in sections that experience more stress or pressure.
Alongside the physical construction, we also plan to revisit the circuit and continue troubleshooting its setup. Our goal is to better understand how all the components work together and ensure that the circuit can be properly integrated into the block structure. This will likely involve reviewing our previous attempts, checking connections, and testing different configurations so that we can achieve a stable and functional setup.
Overall, next week will focus on bringing together both the structural and electrical parts of our project. By continuing to refine the bends, assemble the components, and improve the circuit, we will be moving closer to a fully completed and working final product.
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