Laser cutting

The task for this practical was a group is required to produce a SOP(standard operating procedure) to use for the individual competency test. By having this SOP, we are able to do the competency test with out much trouble and understand the step-by-step procedure of how to use the different laser cutters that are available in the Fablab.

SOP

 A: Safety 

1. 1.Remove any foreign objects around the neck/body to prevent getting tangled into the Machine 

2. 2.Ensure long hair/ fringe is tied up 

3. 3.Lift the cover of the Laser Cutter fully  

4. 4.Do not put your head inside the machine  

5. 5.Do not slam the cover of the machine (as the interlocking light would disappear) 

6. 6.Do not assume LED is spoiled, ensure both Left and Right LED is green/on (See Figure 1)  

7. 
   

     

   Figure 1: Observe for Left and Right LED with Green light 

    

7. 7.Do not lean your body on the cover of the Laser Cutter (as it would trigger the safety interlock and operation of the Laser Cutter would halt) 

8. 8.Do not stare into the beam while cutting 

9. 9.Do not leave machine unattended while cutting/engraving 

10. 10.If a small fire occurs attempt to extinguish by blowing/removing material from laser cutter *Safety Feature: (There is a safety interlock, simply open the Laser cutter cover fully which will aid to stop the beaming of the laser and movement of the head) 

11. 11.If the material cannot be cut through, stop and check - Focus lens might be dirty. 

* Continued use of dirty lens will result in Cracked Lens (See Figure 2) 

 

Figure 2: See Cracked Lens  

 

12. 12.When using the Epilog Software - Remember to on ‘Air Assist’ (if not it will result in Fire) 

 

B. Start up 

1. 1.Turn on the air compressor (See Figure 3 and 4) 

2. 
    

   Figure 3: Air Compressor 

3.  

   
    

   Figure 4: On Switch for Air Compressor 
   

2. 2.Turn on the fume extractor (See Figure 5 and 6) 

3.  

   Figure 5: Perspective of where Fume Extractor is Located  

   – Downwards, Left-Hand side of Machine (see arrow) 

4.  

   
   
    

   Figure 6: Turning on Fume Extractor - Press Green Button  

    

3. 3.Turn on the main laser cutter (See Figure 7) 

4. 
    

   Figure 7: Switching on the main Laser Cutter  

5. 
   

4. 4.Wait until the laser cutter completes initializing [around 1 minute] (See Figure 8) 

5. 
   
   
            

   Figure 8: Wait for Initialization to Complete 

    

5. 5.Proceed to the Workstation i.e., Desktop connected to Laser Cutter 

 

C. Operation (Using CorelDraw):  

*For Basic Features, Refer to Figure 9-12, (See Note below Figure 12 for guidance) 

 

3. Operation (Using CorelDraw) 

 

 

Figure 9: Basic Features of CorelDraw 

 

 

Figure 10: (1): Top Bar Icons and Description 

 

 

Figure 11: (2): Side Bar Icons and Description 

 

Figure 12: (3): Bottom Bar Icons and Descriptions  

**Note: Vector Cut refers to outline of Shape to be cut, Engrave refers to fill of shape to be engraved, Engrave Etch/Score refers to outline of shape to be engraved 

1. 1.File -> Import; Import the DXF file (Fusion 360 File) into CorelDraw  

2. 
   

2. 2.Select the Image after Imported (See Figure 13) 

3.  

   Figure 13: Selecting Drawing 

    

3. 3.Click Bottom Right Corner (Pen and Fill icon) and adjust the appropriate settings i.e. (Colour, Line weight and Fill) for Cutting and Engraving. (See Figure 12) 

 

Figure 12: (3): Bottom Bar Icons and Descriptions  

4. 4.Once done, Press ‘Control +P’, Print box would pop-up, and Select ‘Print’ (See Figure 14) 

5. 
    

   Figure 14: Select ‘Print’ 

 

Page Automatically updates to Epilog Software 

D. Operation (Using Epilog Software)  

 

1.Fusion Pro 

1. 1.Set ‘Autofocus’ -> ‘Thickness’ *Default is off (See Figure 15)  

2. 
    

   Figure 15 

    

2. 2.On the right-hand side, it will show the process of each object’s action which was pre-set earlier when using CorelDraw. Click on each process’s action to check the settings again. (See Figure 16) 

3. 
   
    

   Figure 16 

    

*Note: Any object’s line-weight set as hairline are considered as vector and with thickness is considered as engraving  

 

2.Fusion M2 

1. 1.Set ‘AutoFocus’ -> ‘On’ 

2. 
   

2. 2.Choose ‘Air Assist’ -> ‘On’ for each process 

(For Steps 1 & 2 See Figure 17) 

 

Figure 17 

 

3. 3.On the right-hand side, it will show the process of each object’s action which was pre-set earlier when using CorelDraw. Click on each process’s action to check the settings again. (See Figure 18) 

*Note: Any object’s line-weight set as hairline are considered as vector and with thickness is considered as engraving  

 

Figure 18 

 

E. Material Setting  

 

 1. Load Material Library 

 

1. 1.Click the ‘Folder Icon’ (See Figure 19) to Load Material Library  

*Note: (See Figure 20 for view of Loaded Material Library) 

 

Figure 19: Folder Icon which loads Material Library 

 

 

Figure 20: Loaded Material Library Box 

 

2. 2.Once Material Library has loaded, choose which material to be used for cutting/engraving. Do it for both Processes. Then Click ‘Import’ (See Figure 21) 

3. 
    

   Figure 21: Loaded Material Library to select thickness & type of Material to be used 

4. 
   

3. 3.For Engraving, Select the Engraving Tab and enter the thickness of the material chosen. (See Figure 22) 

*Note: To be able to select a material, you would need to know its thickness so measure its thickness using a Vernier caliper first  

 

Figure 22 

  

4. 4.For Cutting, Select the Vector Tab and enter the thickness of the material chosen. [i.e. Repeat Step 3] 

5. 
   

5. 5.Always Check that ‘Air Assist’ is turned on for FUSION M2 Machine (See Figure 22 – Blue Circle) 

*Refer to Figure 23 for Final Adjustments for Machine in this step.   

 

Figure 22 

 

 

Figure 23: Final Adjustments for Machine 

 

 

 

 

 

 

 

F. Positioning (*If required) 

  

1.Fusion Pro 

 

1. Adjust the position of the material using the build in camera in fusion Pro. (See Figure 24) 

2.  

   Figure 24 

 

2.Fusion M2 

*There is no Built-in camera  

 

1.  Adjust the material using mouse tool on the left bar and adjust base on the location of 2 ruler on the top and left. (See Figure 25) 

  

Figure 25 

G. Print 

Once done, Click on “PRINT” to send file to Laser cutter. It will not cut immediately but to show up on the LCD screen instead. (See Figure 26) 

 

 

Figure 26 

 

1.Fusion Pro: To cut, check file name and estimated time to cut on the LCD touch screen. Once confirm, press the “play button” (See Figure 27) 

  

 

Figure 27 

2.Fusion M2: To cut, check file name and estimated time to cut on the LCD touch screen. Once confirm, press the “Go button” (See Figure 28) 

  

 

Figure 28 

Wait for 1 minute after completed printing  

 

 

H. Shut Down: (Reverse of Start up) 

 

1. 1.Turn off the main laser cutter (See Figure 7)  

2. 
    

   Figure 7: Switching on the main Laser Cutter  

3. 
   

2. 2.Turn off the fume extractor (See Figure 5 and 6) 

3. 
    

   Figure 5: Perspective of where Fume Extractor is Located  

   – Downwards, Left-Hand side of Machine (see arrow) 

    

   
   
    

   Figure 6: Turning on Fume Extractor - Press Green Button  

4. 
   

3. 3.Turn off the air compressor (See Figure 3 and 4) 

By following the SOP, I was able to the individual competency test and produce a laser cut out test piece:

My group was also able to make a parametric construction kit and these were the steps that were taken before doing our laser cutting of the kit.

 

Processes: 

 

 

  

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

2c. CAD Fusion Documentation of 5 Components: (page 8-14) 

 

1. Rectangle: 

 

Select modify and click change parameters 

 

Key in the parameters and values 

 

Select create sketch 

 

Select a plane, click 2-point rectangle and draw a 200 (length) by 50 (width) mm rectangle 

 

 

Select line and draw a diagonal rectangle 10 (sloth) by 7 (shortsloth) by 3 (thickness)mm 

 

Repeat on both sides 4 times 

 

Select center diameter circle and draw 3 mm circle. 

Select 2-point rectangle and draw a 10 (sloth) by 3 (thickness) mm rectangle at the edge of the circle 

 

Right click the circle and click delete 

 

Select finish sketch 

 

Select extrude, click the body and type 3mm (thickness) 

 

 

 

 

2. Square 

 

Select modify and click change parameters 

 

Key in the parameter and value 

 

Select create sketch 

 

Select a plane. Then select 2-point rectangle and type in 40 (length) by 40 mm (length) 

 

Select center diameter circle and draw a 3mm circle at midpoint of the breadth 

 

Select line and draw a 10mm (sloth) line from the edge of the circle 

 

Select line and draw a 3 mm (thickness) line from the line drew previously 

 

Select line and draw a 10 mm (sloth) line from the line drew previously 

 

Right click the circle and click delete 

 

Repeat for all 4 sides 

 

Select extrude and click on the body to extrude by 3mm (thickness) 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. Star 

 

Select modify and click change parameters 

 

Key in parameter and value 

 

Select create sketch 

 

Select a plane, click center diameter circle and draw a 30 mm (length) circle 

 

Select polygon and click circumscribed polygon 

 

Set the diameter of the polygon as 5mm and number of sides as 5 

 

Select horizontal/vertical constrain and click on the polygon 

 

Right click on the sides and click normal/construction 

Repeat for all sides 

 

Select line and draw a line from the edge of the polygon to the circle and back to the other edge of the polygon 

 

Select circular patterns. Click objects and click on the 2 lines previously drew. Then click on center point and click the center of the circle/polygon. Next type 5 patterns 

 

Select extrude and click on the body, type 3mm (thickness) 

 

 

4. 50mm&   5. 30mm circle: 

 

First, set the dimension of the big circle with naming of diameter 50mm and height 3mm under change parameter. 

 

Next, form a circle, for the diameter of circle, select the set diameter of 50 mm 

 

After defining the diameter of circle, select line and mark out the unwanted parts with dimensions of 10mm by 3mm. 

 

To remove the unwanted part of the circle, select trim and click on the unwanted parts. 

 

Lastly, Click finish sketch and extrude the circle to the defined dimension named as height with 3mm thickness. 

 

This is what the final design looks like, repeat the previous steps for the circle with diameter of 30mm. 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

3. Use of Laser Cutter to Cut Parametric Drawing 

 

Referring to SOP we created, we used the FUSION PRO MACHINE and followed all the standard steps for start-up.  

 

Below shows the processes for CorelDraw, Epilogue Software and Cutting: 

 

1. CorelDraw 

 

   à Importing DXF fusion files of 5 objects 

 

  

à Imported 5 objects (Although this image clearly shows the scale at which our objects were and would be cut eventually, we    didn’t realise it at this point and continued to proceed instead of adjusting their dimensions which is why eventually our first batch had the 5 objects cut very small) 

 

We then changed the colour of the outline of the 5 objects to red and changed the line weight to hairline after which we proceeded to click print. Thereafter proceeding to the epilogue software 

 

2. Epilogue Software 

 

 à Our 5 objects as reflected in the blue circle (We still did not realise the scale at this point) 

 

 à Final Settings for Machine (we turned off Engrave and checked the settings for Vector Process after turning on Air Assist) 

We then clicked Print  

 

3. Cutting 

 

  

à After waiting for the screen to confirm the job title and duration for printing, we Pressed ‘Go’ which commenced the Cutting of our 5 objects  

 

 

 à Start of Laser Cutting  

 

  

à This was our final product. At this point, we realized we did not set the proper dimension for our objects to be cut as it was too small which was why we had to redo the process. 

 

 

2nd Batch Laser-Cutting Process 

 

1. CorelDraw 

 

                                    

à We changed the dimension to scale up our product (one example from the 5 components to which we did the same) However, we halfed our actual Fusion 360 Dimensions as we felt that the components would be too large which is why the dimensions they would be cut to would be half of our desired dimensions in Fusion 360.  

 à Comparison of scaled up components [i.e. the 2 circles] versus the ones we had yet to scale up at this point. 

 

  

à As we scaled up our components (the large circle for example), we realised that our lines were not grouped which was why the slots created on the components shifted away, leaving us with drawings that didn’t match our Fusion 360 designs. 

 

 

                                     

à To solve this problem, we tried using the ‘Group’ Function as shown in this Figure. 

 

 

   

 

 

                                         

 

 

• To solve the problem, we managed to delete the circle line outside of the star since it was not grouped to the star itself. However, to get rid of the lines forming the pentagon in the star which also obstructs the slot, we had to use the “virtual segment Delete’ function [see blue circle]. Then we used the cursor and clicked on those lines we wanted to remove to eventually give us the intended shape of the star component  

 

 

                     

 

 

Then we set the correct colour and line weight settings for the corrected components and click ‘Print’ which will go into Epilogue Software 

 

2. Epilogue Software 

 

 

       

 

à after confirming the correct final machine settings and turning the air assist on, we proceeded to click Print 

3. Cutting 

 

 

  

à After waiting for the screen to confirm the job title and duration for printing, we Pressed ‘Go’ which commenced the Cutting of our 5 objects  

 

                                  

• Our batch 2 components, scaled up                                                                                    process 

 

 

Conclusion: Figure of some of Our Final Components: 

 

 

 

Figure showing difference of width of slots accounting for misfit 

 

              VS                    

(Slot of small circle is 3mm)                                                              (Slot of square base is 1.7mm) 

 

• Our final cut Components were too small and could not fit together as a parametric kit. This was because we decided to half our desired dimension from Fusion 360 and when we did it, we did not use the ‘Group’ function to select all the components and change their dimensions uniformly which was why the width of the slots of some components differed and could not have a proper fit.  

 

 

Thus, the following day after our Practical [Friday, 29/10], we had to do a Batch 3.  

 

 

 

Batch 3 – Successful Christmas Tree 

 

      

 

• For this final Batch, we followed all the process of Batch 2 however, for the dimension aspect, we inputted the exact same desired Dimensions we used in Fusion 360 when designing the CAD drawing of every component which ensured that the kerf was accounted for, the scale was accurate and the parametric construction fits.  

 

 

 

Hero Shot 

 

 

Reflection:

For this practical we had to go through a competency test and had to make parametric construction kit. For the competency test everyone was tested individually and had to know how to operate the laser cutting machine safely and correctly and also know how to transfer the 3D drawings to the computer so that the laser cutting could be done.

This practical was important due the fact it shows whether we were competent enough to use the laser cutting machine and if not, we would not be able to proceed with the practical.

I used to think that the laser cutting would be very similar to 3D printing but after going through the lesson and the practical, now I think that they are very different because laser cutting can only work for certain 3D drawings and the drawings had to match the thickness of the material that would be used to laser cut. By learning this skill, it would help me with assignments that require making an item as not only do I have the skills to do 3D printing but also laser cutting making idea generation easier.