Assignment Overview
This page summarizes the comprehensive group assignment from Week 1, where we systematically tested and documented laser cutter parameters for optimal cutting performance, including kerf analysis and clearance measurements.
Group Assignment: Laser Cutter Characterization
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 | Assignment completed: September 16, 2025
Key Results Summary
Average Kerf
Result: 0.0049 inches
High precision with ±0.0017 inches standard deviation
Average Clearance
Result: -0.0045 inches
Interference fit with ±0.0009 inches consistency
Machine Specifications
Available Lasers
COâ‚‚ Laser: 75W (large machine)
COâ‚‚ Laser: 60W (small machine)
Fiber Laser: Back of lab
Test Parameters
Rate: 500 pulses per inch (PPI)
Power: 100%
Speed: 30% (increased by 2.5% each test)
Laser Cutter System Details
Universal Laser Systems CO2 Laser: The system uses Universal Control Software with Inkscape for vector design and cutting. Color-coded line system allows efficient batch processing of both cutting and engraving operations in a single job.
Red lines (0.001") for vector cutting at full power, blue lines (0.001") for raster engraving operations.
Focus & Positioning
Focus Point: Cut at the focal length (white part of the focusing stick)
Kerf Measurement: Measure deltas between intended and actual cut dimensions
Focus Accuracy: Critical for achieving clean, precise cuts
Joint Design & Clearance
Joint Type
Design: Finger joint - interlocking design for structural connections
Clearance Definition
Purpose: Size of the slot that provides tight enough fit for assembly
Material Considerations
Cardboard Limitations: Generally produces no good joints due to material properties and laser cutting characteristics
Material choice significantly impacts joint quality and assembly precision
Key Learnings
Speed increment of 2.5% provides systematic testing progression
Focus accuracy is critical for dimensional precision
Kerf measurement essential for compensating cut width in designs
Material selection directly impacts joint quality and assembly success
Systematic parameter testing reveals optimal settings for different materials
Measurement Methodology
Systematic Approach: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training. Clearance analysis involved three measurements for both hole and peg dimensions.
Clearance = Hole Size - Peg Size (negative values indicate interference fit). Statistical analysis included averages and standard deviations for precision assessment.
Design Test Files
Comprehensive design files for laser cutter characterization and joint testing:
HTMA Joint Test v0 (F3D)
Fusion 360 design file for joint testing
📥 View Files
Crease Pattern Files
Multiple CAD and DXF files for origami patterns
📥 View Files
Special Thanks to Our Section
We would like to express our sincere gratitude to all members of our section for their invaluable collaboration throughout this laser cutter characterization group assignment. Your contributions were essential to the success of this comprehensive testing project.
Collaboration Activities
Laser cutting coordination and scheduling
Measurement documentation and data collection
Photo documentation and sharing
Slack discussions and troubleshooting
Knowledge Sharing
Measurement techniques and precision methods
Technical insights and observations
Statistical analysis and data interpretation
Results validation and methodology refinement
This collaborative effort demonstrates the power of teamwork in technical education and research. The collective knowledge and shared experiences significantly enhanced the quality and depth of our laser cutter characterization methodology.
Ethical AI Use
Documentation of AI tool usage for this week's group assignment summary and website development work.
Week 2 - Laser Cutter Characterization Summary Development
This session covers the development of the Week 2 page summarizing the laser cutter characterization group assignment from Week 1, including content extraction, methodology documentation, and comprehensive results analysis.
Key AI Activities
Content Extraction
Systematic extraction and summarization of laser cutter characterization results from Week 1 materials
Methodology Documentation
Implementation of measurement protocols and statistical analysis documentation
Website Structure
Creation of responsive HTML structure with comprehensive test result documentation
Navigation Integration
Addition of Week 2 link to main index page for seamless course navigation
AI Tools Used
Cursor AI
Code generation, content structuring, and website development assistance
Content Analysis
Systematic review and extraction of relevant information from existing course materials
Link Management
Implementation and validation of links to external design files and detailed documentation
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Group Assignments
Assignment 02
Assignment 03
Assignment 04
Assignment 05
Assignment 06
Assignment 07
Students
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Perfect! I have successfully completed all the requested tasks:
## Summary of Completed Work
✅ **Created Week2.html** - I created a new HTML file based on the structure of Week4.html, but customized it for the laser cutter characterization assignment from Week 1.
✅ **Updated index.html** - I added "Assignment 02" as a new link in the Group Assignments section, positioned before Assignment 03.
✅ **Summarized Group Assignment** - I extracted and summarized the key content from the laser cutter characterization group assignment section in week1 copy.html, including:
- Key results (Average Kerf: 0.0049 inches, Average Clearance: -0.0045 inches)
- Machine specifications and test parameters
- Laser cutter system details
- Focus & positioning methodology
- Joint design & clearance concepts
- Material considerations
- Key learnings and measurement methodology
- Design test files references
✅ **Added Full Details Link** - I included a prominent link to the full details at `https://fab.cba.mit.edu/classes/863.25/people/SaleemAldajani/week1.html#laser-assignment` in a highlighted box at the top of the page.
The Week2.html page now provides a comprehensive summary of the laser cutter characterization group assignment while maintaining the same professional styling and structure as the other assignment pages. The page includes all the essential information about the assignment, results, methodology, and provides clear navigation to the full detailed documentation.