Weekend Builds: Laser Slicing and Engraving

With regards to digital fabrication, MatterHackers is your one-stop-shop for all of your gear and materials wants, like laser cutters and engravers. Whereas we stock a number of completely different machines, this text goes to give attention to the FSL Muse and the companion software program, Retina Engrave 3, just because I’m most accustomed to that laser cutter and its workflow.

There’s a number of various things you may really do together with your laser cutter upon getting it, greater than I may even consider. To present you an thought of what you are able to do, I’m going to work on three completely different initiatives round three completely different ideas: reconstructing a 3D mannequin, engraving a sample, and creating customized packaging. Let’s get to it!

Laser Slicing a 3D Mannequin

Autodesk has a extremely helpful program that can take an imported 3D mannequin and slice it into layers that may then be despatched to your laser cutter or lower out by hand: Autodesk Slicer for Fusion360. Whereas this slicer works very equally to a slicer for a 3D printer, it’s options and performance are tailor made for laser reducing.

You begin off by importing your 3D mannequin, which can pop in a bunch of latest settings like how huge would you like your completed object with a preview of it on the proper facet. The very first thing it would be best to do is choose your “Manufacturing Settings” which is the scale of your materials in X, Y, and Z. You may both choose from a drop down of fabric choices, or you may create your individual materials. It is advisable to be very particular on the thickness of your materials, in any other case a sphere could look extra like an egg by the point you’re completed.

When you’ve acquired your object and materials settings proper, you may select your building approach.

• Stacked slices works virtually precisely like 3D printing; it cuts your object into layers that may then be glued collectively to recreate your form. The “decision” of your end object is restricted by your materials thickness in the identical manner. This would be the technique I give attention to at the moment.
• Interlocked slices cuts your 3D mannequin in two perpendicular planes, then provides slots to the silhouettes. All of the items will slot collectively to kind your object, nevertheless some fashions could not work on this technique, on account of both overlapping slots with oddly formed fashions and even elements that find yourself too small the slot into something.
• Curve is like interlocked slices, besides the second set of items are at an angle as a substitute of parallel with an axis.
• Radial has interlocking slices begin from a central level on the 3D mannequin.
• Folded Panels takes the polygons of your 3D mannequin and flattens it out so you may print it out and fold it again collectively to create your object. This actually solely works for fashions with a decrease poly depend slightly than something with excessive element.
• 3D Slices appears to be a strategy to slice you mannequin into layers with out altering or estimating its geometry, however you may’t really use or export this.

Stacked slices will carry probably the most element out of your 3D mannequin, at the price of extra materials and time, however the finish end result will look that significantly better! You may select so as to add dowels by means of your mannequin for rigidity, however in my case this deer head doesn’t have sufficient house for a dowel to do a lot good. I may change the slice course to get extra element, identical to rotating a mannequin for 3D printing to prioritize element. As soon as I’m pleased, I’ll click on “Get Plans” to be prompted to export the cutouts in sheets as DXF, EPS, or PDF. DXF goes to be the only option for laser reducing in my case, however your laser cutter’s software program could want a distinct file format. In that case you need to use a web based converter to get to the proper file kind. Ensure to save lots of this mission so you know the way to assemble it later; there will likely be a number of items!

Now that I’ve the plans for it, I can import these into RE3. As soon as it’s been processed I can take away the total picture layer (which could possibly be used to raster/engrave this onto my materials) and ensure my sizing is appropriate, as a result of generally that may get misplaced transferring from one software program to a different. It would be best to do some take a look at cuts first on some scrap materials to see the mix of energy, velocity, and present you’ll want to chop by means of your materials. For the FSL Muse, I used 25% energy, 100% velocity, and 100% present for 3/16” cardboard and that labored very well.

As an increasing number of items had been lower out, the immense puzzle started to come back collectively. Checking backwards and forwards between the meeting steps and what I had lower out, I used to be capable of put collectively subassemblies because it progressed, till lastly the final sheet was executed and I may sizzling glue and tremendous glue the previous few items collectively.

Engraving an Picture

This is without doubt one of the easiest mission you are able to do on a laser engraver. The one prep work that’s wanted is to measure out the fabric you’re going to make use of and give you a plan of what you need to engrave onto it.

From there, you may both bounce into your favourite picture enhancing software program, make the most of the instruments throughout the laser cutter software program (fundamental instruments like textual content and shapes) or import a photograph to transform and engrave throughout the software program. Dylan threw collectively a fast design to commemorate our Group Hex Wall which I may then import into Retina Engrave 3 and tune my engrave settings. I’m going to be engraving on a chunk of Cherry MatterHackers Mission Wooden and with a pleasant piece of wooden like this, I don’t need to be too aggressive it, for concern that it’ll burn too strongly. As an alternative, with one thing like this the place you don’t have an opportunity to do some assessments, it’s higher to start out with a decrease energy setting and do a number of passes.

For this plaque, we ended up doing two passes at 50% energy and 100% velocity, and that gave it a pleasant contrasting colour with some good depth to it. Engraving took solely a half hour, together with the time to design it, prep the laser cutter, and prep the settings wanted for the design. If this had been one thing you wished to do batches of, it will be even faster to perform upon getting the approach right down to a science.

Customized Foam Packaging

I’ve had a bit of device case for over a 12 months now that I wished the proper use for, and with the Nintendo Swap being such a enjoyable and well-liked merchandise proper now with Tremendous Smash battles no less than as soon as per week within the workplace, it made sense to make it a case for a Swap controller.

Venegade on Thingiverse designed a extremely cool grip for the Joycons that I’ve printed and would make designing a case very easy. All I needed to do was import some Swap controller stand-ins and line them up within the controller case, colour the fashions black to make it simpler to hint, then take a screenshot from a entrance dealing with view. From there I may cross it off to Dylan to create an SVG, or vector, file utilizing Adobe Illustrator.

Simply the identical as all the remainder, I may import this SVG file into RE3 and set the laser energy for the packing foam in it, and identical to the Mission Wooden, I solely had one piece to make use of for testing and ultimate model. To play it secure, I set the laser energy to fifteen%, velocity to 100%, and present to 100%, and surprisingly it lower by means of the froth like butter after the primary cross. A pair dabs of tremendous glue and now I’ve a customized case the securely protects my Swap Joycons for gaming on the go.

Whether or not you’re trying to create your subsequent hit product or simply one thing enjoyable to place collectively, every of those initiatives ought to hopefully get some gears turning and encourage you to attempt it out. Share with me on Twitter what you have created, I might like to see it!

Completely satisfied lasering!