Digital Fabrication 101 :
Laser Cutting
In higher-fidelity cardboard models, the pieces might be laser cut, and other materials might be introduced to work with the cardboard pieces (including motors/ electronics).
Prototype One
Prototype Two
Prototype Three
Iteration
Digi-Fab
A Collection of Tools
Digital fabrication refers to the use of computer-controlled tools and processes to create physical objects from digital designs. It's an umbrella term that encompasses various technologies, including 3D printing, laser cutting, CNC machining, and more
3D Printer
Laser Cutter
Vinyl Cutter / Plotter
CNC Milling Machine
Waterjet Cutter
Laser Cutting
What Is It?
Laser cutting is a manufacturing process that uses a high-powered laser beam to cut, engrave, or etch materials into specific shapes or designs. This process is controlled by a computer and is often used on materials like wood, metal, plastic, and fabric. The laser precisely follows a digital design, allowing for intricate and accurate cuts and engravings.
WHAT CAN A LASER CUTTER DO?
Cut
The laser cutter directs the beam of a laser to burn through the material in whatever pattern you design
Etch
The laser cutter can decrease the laser power to burn the surface of the material, but not cut through
Laser Cut
Laser Engraving
MATERIALS
Cardboard 3/16”
Ensure it is laying flat
Cardstock Paper 60lb or thicker
Be careful to watch while cutting
Plywood & Hardwood 1/8" or thinner
Baltic Birch plywood is best
Acrylic 1/8" or thinner
Don’t cut any other types of plastics
Leather 1/8" or thinner
Ensure it is laying flat
Glass and Metal Etching only
Cannot cut through
3D Printing
Laser Cutting
Can create more complex parts
Low cost & less waste
Huge support community
Generally slower than laser cutting
Post processing may be required
More experience needed to 3D model parts
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Extremely fast & precise
Can quickly etch details
Material range
Requires active ventilation
Higher cost
Less community support
VS
Mock up Prototype
Final Prototype
Sketch
Process to Digital Fabrication
Mindfulness Eating Kit
Low-Fidelity
High-Fidelity
Realistic Motion Wings
Green Planet
Software
To laser-cut your design, export it as an SVG (vector) file and send that to the printer or laser-cutting service. There are many programs and workflows you can use to create SVGs.
- XTool (Free, very easy)
- Inkscape (free, intermediate)
- Adobe Illustrator (, intermediate)
- Fusion 360 (Free for educators , intermediate)
- AutoCAD (License needed , intermediate)
- Rhino ( License needed , Advanced )
File types [SVG / DXF]
Designing for Laser Cutting
Designing for Laser Cutting
When designing, you must think like the machine.
Design rules
- Lines = cuts
- Closed shapes cut out
- Stroke color or thickness often defines cut vs score
Important
- No overlapping lines (or danger of burning)
- Use vectors, not images
- Keep designs flat (2D)
Black: Cut & Green: Scoring
Laser Cutting Applications
Press Fit Designs
Simple Boxes
Laser cutting is great for building without glue.
Furniture/Architectural Structures
Laser Cutting Applications
Press Fit Designs
Waffle
NuVu Examples
Waffle Cyclinder
Layered Cyclinder
Laser Cutting Applications
Mechanisms
Laser-cut parts can create moving systems.
Automata
Series of mechanism
Iris Shutter
Laser Cutting Applications
NuVu Examples
Cardboard Mechanisms
Laser Cutting Applications
NuVu Examples
Eccentric Cam
Scissor Lift
Wooden Mechanisms
Servo Arm
Planetary Gears
Barrel Cam
Parallel Linkage
Linear Ratchet
Piston
Laser Cutting Applications
NuVu Examples
Wooden/Cardboard Mechanisms
Cardboard
Wood
Cardboard
Laser Cutting Applications
Kerfing
Solid materials don’t like to bend.
Kerfing creates tiny gaps that allow movement.
More cuts → more flexibility
Fewer cuts → stiffer structure
The word “kerf” = the width of material removed by the laser
Always do a test strip first:
- Same material
- Same thickness
- Different spacing
Laser Cutting Applications
Kerfing
NuVu Examples
Laser Cutting
Student Work
The "Klutz" Robot
Lottery Pig
Rivalship
Octo
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