Introduction
In Project 5, we explored the world of laser cutting, tasked with creating a customized enclosure for our alarm clocks. This assignment marked a notable shift in our learning experience, introducing us to reductive manufacturing through digital fabrication. The project required meticulous attention to detail, precision measurements, and multiple iterations to achieve a suitable fit and assembly. Here, I will share my experiences, challenges, and achievements throughout this project.
Taking Precise Measurements
One of the key takeaways from this project was the importance of accurate measurements. To design a laser-cut enclosure that met the project's criteria, I measured my alarm clock's height, width, and depth. Additionally, I considered the dimensions needed for the screen, buttons, sound output, and battery replacement. These meticulous measurements formed the foundation of my design. I included a detailed drawing with dimensions in my plan, ensuring I had a clear visual representation before diving into the digital design phase.
Designing with Fusion 360
The heart of this project was the use of Fusion 360 to create the laser-cut enclosure design. This versatile software enabled us to work with 3mm materials and account for tolerances and assembly requirements. The enclosure had to fulfill four essential functions: display the screen, provide access to the buttons, allow sound to pass through, and enable battery replacement. My design underwent multiple iterations, each revealing new challenges and demanding further adjustments.
My first attempt was a partial enclosure without holes for the clock's elements. It quickly became apparent that I hadn't considered the material's thickness, leading to issues with the side pieces fitting correctly. After modifying the design, I encountered another challenge—when the alarm clock was placed inside, it rose by 3mm, causing misalignment of the holes and preventing the box from closing. This necessitated another round of adjustments and measurements.
The final piece of the puzzle was addressing the cable connecting the alarm clock to the battery. To accommodate this cable, I added two holes to one of the side pieces, allowing it to pass through, connect to the battery, and neatly exit the enclosure.
Exporting and Laser Cutting
Once satisfied with my design in Fusion 360, I exported it in DXF format, preparing it for laser cutting. Using LightBurn software, I configured the settings to cut MDF particle board. The important settings are 100% power and 20% speed for the Mira 7 machine they were cut on. With the guidance of our professor, we executed the laser cutting process in the classroom. It only took a few minutes for the laser cutting to finish. It was interesting for me to think about how long it took me to design the enclosre on Fusion 360 compared to how short the laser cutting machine took to cut the pieces of my enclosure.
Documenting Difficulties
The most challenging aspect of this project was diagnosing issues with the laser-cut pieces and implementing necessary modifications in Fusion 360. This process highlighted the complexity of Fusion 360 but also its versatility and potential for intricate designs. It was a journey of trial and error, where each iteration brought me closer to a successful laser-cut enclosure. Through persistence and gradual learning, I honed my skills with Fusion 360.
I must acknowledge the invaluable assistance of my TA, Vincent, who provided crucial guidance in the early stages of my design. His support was instrumental in navigating the intricate world of Fusion 360, and it gave me the confidence to tackle similar design projects independently in the future.
Conclusion
Project 5, the laser-cut alarm clock enclosure, was a learning experience that challenged my design and problem-solving skills. Laser cutting took much less time than designing the enclosure. This project emphasized the significance of precise measurements and the need for multiple iterations to achieve the desired outcome. Despite the initial difficulties, I gained a deeper understanding of Fusion 360 and digital fabrication processes. This project served as a testament to the power of persistence and learning from our mistakes, ultimately empowering me to tackle more complex design challenges with confidence.
