EngiMerse - Week 2

Week 2 Log: The Custom Laser-Cut Coaster

Project Status: Completed | Focus: Vector Design, CAM & CNC Machining

Project Overview

For the next phase of my Maker Diploma, I stepped away from the breadboard and into the world of Digital Fabrication. The goal was to design and manufacture a custom wooden coaster using laser cutting technology. The challenge wasn't just cutting a shape, but engineering a functional layout that perfectly accommodates both a standard mug and a spoon, complete with custom engraving.

This project served as my introduction to "Subtractive Manufacturing." It required mastering the full production lifecycle: creating precise vector geometries in CorelDRAW, configuring the laser parameters in RDWorks, and operating the machine to transform a raw 6mm wood sheet into a polished, functional product.

Tools & Software

Design Software: CorelDRAW (For creating precise vector geometries).
CAM Software: RDWorks (To convert vectors into machine instructions).
Fabrication Hardware: CNC Laser Cutter.
Stock Material: 6mm Plywood Sheet.

The Design Process: Architecture

The structural design was engineered to be both aesthetic and functional, accommodating specific dimensions for usage.

1. The Chassis (Base Dimensions) I started by defining the footprint of the coaster. I created a rectangle measuring 150mm x 140mm. To remove sharp edges, I applied a Corner Radius of 24mm, giving it a smooth, modern profile. Finally, I added an internal Contour of 2mm to create a decorative border.

2. Functional Compartments Once the base was set, I engineered the specific holding zones:

The Cup Zone: A circle with a Diameter of 85mm (plus a 2mm contour) to securely hold a standard mug.
The Spoon Zone: A dedicated slot measuring 28mm x 85mm, positioned alongside the cup holder. I applied rounded corners and a contour to match the main body's design language.

Vector Protocols (Color Mapping)

With the geometry defined, I moved on to the "wiring" of the design—assigning specific rules for the laser to follow using color coding.

The Etching System (Red Layer) To engrave the decorative elements (text and coffee bean graphics), I used the Red color channel.

Settings: The Outline color is set to Red, with "No Fill" selected.
Typography: All text was "Converted to Curves" (Ctrl + Q) to ensure the machine reads it as a shape path rather than a font, preventing errors.

The Cutting System (Black Layer) To slice through the 6mm wood, I used the Black color channel.

Settings: The Outline color is set to Black.
Line Weight: Crucially, the line width was set to "Hairline" so the laser interprets it as a cut path rather than a thick raster line.

Configuring typography for the laser: converting to curves, removing the fill, and setting the outline to 'Hairline'.

The Logic (Machine Configuration)

The "software logic" here involved configuring the RDWorks environment to communicate with the machine.

Layer Configuration: I imported the file into RDWorks and mapped the colors to machine operations:

Red (Scan): Configured for surface engraving (7afr).
Black (Cut): Configured to penetrate the full 6mm thickness.
Note: Speed and power settings were calibrated based on the specific density of the wood.

The configuration map shows the dual-process setup: the Red layer is assigned to 'Scan' (etching), while the Black layer is assigned to 'Cut'.

PRO-TIP: Before sending the job to the machine, I use the Preview Tool located in the top toolbar. This feature simulates the laser head's path to verify accuracy.

Green/White Lines: Indicate the scanning/etching path.
Black Lines: Indicate the cutting path.

Origin & Execution:

Zeroing: I determined the "Start Point" or Origin of the laser head on the material.
Sequence: The machine processes the Scan (Red) first to preserve stability, then performs the Cut (Black) to release the final piece.

Final Thoughts

"From Vector to Reality." This project was a deep dive into subtractive manufacturing. Learning to balance design constraints (like corner radii) with machine requirements (hairline thickness and color mapping) was a crucial step in my development as a Maker. The result is a clean, functional piece of hardware that lives on my desk.

Left: The CNC execution showing the etching and cutting passes. Right: The final deployed prototype in its intended environment.

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