Week 2 · Computer-Controlled Cutting

Overview

This week focuses on computer-controlled cutting techniques, including laser cutting and vinyl cutting. Following the How to Make Almost Everything curriculum, I explored the capabilities of these fabrication tools through material testing and parametric design. I was particularly interested in investigating flexure mechanisms and testing the bending abilities of cardboard material to understand how it could be used for compliant mechanisms and kinetic structures.

Material Testing: Joint Tolerances and Kerf

Before proceeding with the final design and laser cutting, we conducted kerf tests to determine the optimal joint tolerances for cardboard assembly. These tests involved cutting a series of slots with varying widths to identify which dimensions would allow two pieces of cardboard to fit together securely without being too loose or too tight. Through systematic testing, we discovered that a tolerance range of 3.25mm to 2.5mm provided the best friction fit, ensuring the pieces would interlock firmly while still being able to assemble without damaging the material.

Design Process: Parametric Flexure Exploration

I used Rhino and Grasshopper to generate various flexure pattern iterations, testing different geometric configurations to achieve the desired bending behavior. Through multiple design versions, I found that only the first and third patterns in the first row met my expectations for controlled elastic deformation. The tilted cutting lines required careful adjustment of the flexure patterns to ensure proper alignment and functionality. A critical consideration was monitoring the edges to verify that the cutting lines and flexure patterns would not interfere with each other or get cut off during fabrication.

Laser Cutting: Flexure Testing

My primary exploration this week centered on understanding material flexure. Flexure mechanisms rely on elastic deformation rather than traditional joints, making them ideal for creating motion without friction or wear. I designed and fabricated a series of test pieces from cardboard to evaluate its bending characteristics, compression behavior, and structural limits under different loading conditions.

Vinyl Cutting

In addition to laser cutting, I experimented with the vinyl cutter to create precise adhesive graphics. Following the How to Make Almost Everything curriculum, this assignment required learning to operate the vinyl cutter, understanding material handling, and mastering the weeding process.

The vinyl cutting process begins with preparing vector artwork in design software, ensuring all paths are properly closed and scaled to the desired dimensions. The vinyl material is loaded onto the cutter's backing sheet and fed through the machine's roller system. Proper material alignment and blade depth adjustment are critical—the blade must cut through the vinyl layer without penetrating the backing paper. After running the cutting job, the excess vinyl is carefully removed in a process called "weeding," leaving only the desired design adhered to the transfer tape for final application.