This week we have been tasked with creating a children’s construction kit using computer controlled cutting. The project asks us to design, cut and assemble a 3D model using computer controlled cutting, I will do this using a laser cutter. Immediately my mind wondered to the wooden 3D dinosaur puzzles I had as a child. This is where I will begin to research for this week.
An example of a wooden dinosaur 3D puzzle
After doing some research into this, I considered what I could create using this technique and decided I wanted to go with something along the lines of a project I created before attending Uni, in which I 3D modelled and printed a TIE fighter from Star Wars. This is something I found exciting and wanted to mass produce but 3D printing it was not the most efficient way by far. So I decided to combine the projects to take them both to the next level.
The 3D model and final print of the TIE fighter I designed.
The next step in the project is to create a new model of the TIE fighter in Solidworks, that is to scale of the model and can be converted into a DXF to be laser cut. I began by creating the wings, as it is the most iconic part and takes up two thirds of the ships main structure. I did this by sketching the wing and then using the smart dimension tool to scale it correctly. I then extruded the wing to 3mm, as it will be cut from 3mm MDF.
The sketch and dimensions of the wings.
The 3D version of the wings.
The next step is to create the centre part, which includes the cockpit and struts. The main thing to consider here is the spacing of the connecting parts between the wings hole and the struts. By this I mean, I need to consider the sizes, so that they fit snuggly and do not fall apart easily, but at the same time I need to compensate for the small amount of material lost when the laser cuts the material.
The Sketch of the Cockpit piece.
The 3D Model of the TIE cockpit.
Now I have all of the parts have been created, I can now put them together as an assembly. The centre part of the TIE will be made using multiple layers of cutouts to form a thicker piece whilst still retaining the shape. The benefit of using computer aided design for this project is that you can make adjustments to the design if you were to find any issues with it.
This is the model with all parts assembled.
These parts of the model will be cut using a laser cutter from 3mm MDF.
In this next section of the weekly project I will talk about how I am going to use computer controlled cutting to create a sticker to add details to the model TIE.
The best way to go about doing this would be to create a sticker as a .ai file and then submit that to the vinyl sticker cutting machine in the Fablab at university. Due to the university being closed I am currently unable to cut the sticker out, however I can still design the sticker ready for it to be cut. I will make a sticker for the details of the ship on the wings so they are not just plain.
The first step of the process is to create or find the image you wish to create an image that you wish to make into a sticker.
Once you have done that, in illustrator, you need to open the file, go to ‘Object’ > ‘Image Trace’ > Make and Expand. This will allow you to edit the sticker so it becomes a tracing object and the vector paths can be adjusted. It will make the image become a silhouette.
Sticker with Vector paths.
This should then be saved as the previously mentioned .ai file and sent to the vinyl sticker cutter in the fablab. You will need to set up the vinyl cutter using the very useful guide created by my lecturer. This can be found here: https://blogs.brighton.ac.uk/covill/2020/02/18/guide-to-using-the-roland-gs-24-vinyl-cutter/ .
