Laser Cutter Assignment Section
Cursor AI Transcript · HTMAA 2025
Table of Contents
Overview
Complete transcript of adding laser cutter assignment section
Full Conversation
I'll open week1.html to find the laser cutter assignment area and add a new "handfolding" section with your images and a refined description.
I’m going to add a new subsection under the Laser Cutter Characterization Group Assignment in week1.html, titled “Hand‑folded Prototype Assembly,” with your five images organized into Single Gadget and Double Gadget groups, plus an insertion close‑up, and a refined description.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
You can find it now in week1.html, and the images are referenced from week1/lasercutter/handfolding/.
I'll move the new hand‑folding subsection from the Laser Cutter Characterization section to the Parametric Construction Kit section and ensure the images and text remain intact.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
Moved. The “Hand‑folded Prototype Assembly” subsection now lives under “Parametric Construction Kit Individual Assignment,” with the same grouped images and refined description.
I'll look for images in week1/lasercutter/fullpatternfailure/ and then add a “Full Pattern Failure” subsection directly under the hand‑folded section with a brief explanation and an image gallery.
Adding a new “Full Pattern Failure” subsection under the existing hand‑folded area with your three images and a concise explanation.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
Added “Full Pattern Failure” under the hand‑folded section with a brief note and an image gallery referencing:
fullpattern.jpegfullpatterncutting.jpegfullpatterncut.jpegLet me know if you want different wording or a separate card instead of a nested subsection.
I'll update the image order in the “Full Pattern Failure” subsection to show cutting first, then the cut result, then the full pattern layout.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
Reordered. The gallery now shows:
1) fullpatterncutting.jpeg
2) fullpatterncut.jpeg
3) fullpattern.jpeg
I'll inspect the media files in week1/lasercutter/firstsuccess/ to determine exact filenames, then add a “First Success” subsection under the existing “Full Pattern Failure” block with the requested order, captions, and brief descriptions.
I'll add the “First Success” subsection under the existing “Full Pattern Failure,” embedding your videos and images in the requested order with concise captions.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Kerf and Side Checks
Measurements confirming mountain vs valley sides and clearances.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
If you want alternate captions or different section titles, I can tweak quickly.
I'll first check what images are available in the firstsuccess directory, then update the section title and add the new "First Success Assembly" section with the Amazon cardboard progression.
I need to check if there are additional files with the names you mentioned. Let me search for files with "quadruple" and "amazon" patterns:
Let me check if there are any other subdirectories or if the files might be in a different location:
Perfect! I found the files in firstsuccessassembly/. Now I'll update the section title and add the new assembly section with the Amazon cardboard progression.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
Now I'll add the new "First Success Assembly" section after the existing single gadget section:
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
First Success Assembly
Switched to thinner Amazon cardboard because the shop cardboard was too thick for the assembly pocket.
The Amazon box folded by hand fit perfectly and assembled smoothly. Three gadgets worked with the thinner
material. Rubber bands are just for compression — they assemble without them, though the bands make it
easier to keep them as one unit during insertion into the next gadget.
Quadruple Cut Strategy
Scaling up to quadruple cuts: sequential cuts, flips between sides, and opposite-side cutting strategies.
Double Gadget — Amazon Cardboard (No Support)
Three views of the double gadget assembled with Amazon cardboard, showing clean folds and proper fit.
Assembly Process with Support
Assembly sequence showing compression, support positioning, and insertion process for stable construction.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
Perfect! I've successfully:
1. Changed the section title from "First Success" to "First Success Folded Single Gadget" 2. Added a new "First Success Assembly" section with: - Refined description about switching to Amazon cardboard - Quadruple Cut Strategy videos (cuts, flips, opposite cuts) - Double Gadget — Amazon Cardboard (No Support) with 3 views - Assembly Process with Support showing crushing, support positioning, and insertion - Triple Gadget — Final Assembly as the culmination
The progression builds from single gadget → double gadget → triple gadget, showing the evolution of your assembly technique with the thinner Amazon cardboard material. Each section has descriptive captions and builds toward the final triple gadget achievement!
I'll look for the thickening images to include, then add the new refinements section and update the Ethical AI section with the chat link and summary.
I'll add a new section “Further Refinements: Thick Origami” under the Parametric Construction Kit area with images, citation, description, and pseudocode, then update the Ethical AI section with the ChatGPT link and summary.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
First Success Assembly
Switched to thinner Amazon cardboard because the shop cardboard was too thick for the assembly pocket.
The Amazon box folded by hand fit perfectly and assembled smoothly. Three gadgets worked with the thinner
material. Rubber bands are just for compression — they assemble without them, though the bands make it
easier to keep them as one unit during insertion into the next gadget.
Quadruple Cut Strategy
Scaling up to quadruple cuts: sequential cuts, flips between sides, and opposite-side cutting strategies.
Double Gadget — Amazon Cardboard (No Support)
Three views of the double gadget assembled with Amazon cardboard, showing clean folds and proper fit.
Assembly Process with Support
Assembly sequence showing compression, support positioning, and insertion process for stable construction.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Further Refinements: Thick Origami
Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
Guidance from Erik Demaine
Summary: Based on a discussion with Erik Demaine, I explored thick‑origami methods where each crease is
doubled into parallel offsets and vertex regions are opened as polygons to prevent collisions. An initial
uniform spacing works, but to be truly correct, the spacing between doubled creases should depend on the
number of layers between faces in the final folded state. I will instrument the fold to estimate per‑crease
layer counts and adjust offsets accordingly.
Reference suggested by Erik Demaine: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”,
Journal of Mechanisms and Robotics, 8(3), June 2016, pp. 031003‑1–6.
View paper
Thickened Crease Patterns
Two approaches generated for my pattern:
- Estimate: double each crease with uniform offset and place regular polygons at intersections.
- Exact: compute sector‑aware offset polygons at vertices using the incident crease angles.
How the Estimate Works
Simple and robust; good for fabrication trials.
Input: crease segments with mountain/valley labels; sheet size S; target thickness t
offset = t / S (or a chosen fraction)
for each crease c:
draw two lines parallel to c at ±offset
for each vertex (intersection of original creases):
place a small regular polygon (e.g., octagon) centered at the vertex
Output: doubled creases + vertex holes
How the Exact Method Works
Sector‑aware vertex polygons following Ku–Demaine.
Input: crease lines; sheet size S; target thickness t
offset = t / S
for each crease c:
compute unit direction v and normals n1,n2
define two infinite offset lines at ±offset along n1/n2
for each vertex:
collect incident creases; sort by angle into cyclic order
for each adjacent pair (i, j):
pick the offset side that lies inside the angular sector
intersect those two offset lines → one polygon vertex
connect all vertices in order → convex vertex polygon
trim faces/creases by polygons as needed
Output: doubled creases + exact vertex polygons
Adjusting for Layer Counts (Next Step)
Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: instrument the folding to estimate per‑crease layer counts, then set per‑crease offset = k × thickness × layers(c), keeping polygons valid and avoiding collisions.
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
First Success Assembly
Switched to thinner Amazon cardboard because the shop cardboard was too thick for the assembly pocket.
The Amazon box folded by hand fit perfectly and assembled smoothly. Three gadgets worked with the thinner
material. Rubber bands are just for compression — they assemble without them, though the bands make it
easier to keep them as one unit during insertion into the next gadget.
Quadruple Cut Strategy
Scaling up to quadruple cuts: sequential cuts, flips between sides, and opposite-side cutting strategies.
Double Gadget — Amazon Cardboard (No Support)
Three views of the double gadget assembled with Amazon cardboard, showing clean folds and proper fit.
Assembly Process with Support
Assembly sequence showing compression, support positioning, and insertion process for stable construction.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Further Refinements: Thick Origami
Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
Guidance from Erik Demaine
Summary: Based on a discussion with Erik Demaine, I explored thick‑origami methods where each crease is
doubled into parallel offsets and vertex regions are opened as polygons to prevent collisions. An initial
uniform spacing works, but to be truly correct, the spacing between doubled creases should depend on the
number of layers between faces in the final folded state. I will instrument the fold to estimate per‑crease
layer counts and adjust offsets accordingly.
Reference suggested by Erik Demaine: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”,
Journal of Mechanisms and Robotics, 8(3), June 2016, pp. 031003‑1–6.
View paper
Thickened Crease Patterns
Two approaches generated for my pattern:
- Estimate: double each crease with uniform offset and place regular polygons at intersections.
- Exact: compute sector‑aware offset polygons at vertices using the incident crease angles.
How the Estimate Works
Simple and robust; good for fabrication trials.
Input: crease segments with mountain/valley labels; sheet size S; target thickness t
offset = t / S (or a chosen fraction)
for each crease c:
draw two lines parallel to c at ±offset
for each vertex (intersection of original creases):
place a small regular polygon (e.g., octagon) centered at the vertex
Output: doubled creases + vertex holes
How the Exact Method Works
Sector‑aware vertex polygons following Ku–Demaine.
Input: crease lines; sheet size S; target thickness t
offset = t / S
for each crease c:
compute unit direction v and normals n1,n2
define two infinite offset lines at ±offset along n1/n2
for each vertex:
collect incident creases; sort by angle into cyclic order
for each adjacent pair (i, j):
pick the offset side that lies inside the angular sector
intersect those two offset lines → one polygon vertex
connect all vertices in order → convex vertex polygon
trim faces/creases by polygons as needed
Output: doubled creases + exact vertex polygons
Adjusting for Layer Counts (Next Step)
Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: instrument the folding to estimate per‑crease layer counts, then set per‑crease offset = k × thickness × layers(c), keeping polygons valid and avoiding collisions.
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
First Success Assembly
Switched to thinner Amazon cardboard because the shop cardboard was too thick for the assembly pocket.
The Amazon box folded by hand fit perfectly and assembled smoothly. Three gadgets worked with the thinner
material. Rubber bands are just for compression — they assemble without them, though the bands make it
easier to keep them as one unit during insertion into the next gadget.
Quadruple Cut Strategy
Scaling up to quadruple cuts: sequential cuts, flips between sides, and opposite-side cutting strategies.
Double Gadget — Amazon Cardboard (No Support)
Three views of the double gadget assembled with Amazon cardboard, showing clean folds and proper fit.
Assembly Process with Support
Assembly sequence showing compression, support positioning, and insertion process for stable construction.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
AI-Assisted Thick Origami Conversion
A separate chat was used to convert a flat crease pattern into a thick‑origami version following Ku & Demaine.
The AI doubled each crease into parallel offsets and generated vertex polygons (estimate = regular polygons; exact = sector‑aware polygons) and explained how to map desired thickness by setting OFFSET_FRAC = thickness / sheet_size.
week1/lasercutter/thickening/ showing both estimate and exact conversions.
- Concise pseudocode blocks for the estimate and exact methods.
- A plan to adjust offsets per crease based on the number of layers.
OFFSET_FRAC = thickness / sheet_size maps desired thickness.
If you want the pseudocode styled differently or placed side-by-side with the images, I can tweak the layout.
I'll move the “Further Refinements: Thick Origami” content to be a nested subsection under the Parametric Construction Kit section after the Triple Gadget, and remove the standalone section.
I'll add the “Further Refinements: Thick Origami” as a nested subsection right after the Triple Gadget within the Parametric Construction Kit section, using consistent header levels, and keep the Ethical AI additions as-is. Now making the edit.
* Begin Patch
* Update File: /Users/saleem/MIT/classes/htmaa_25/week1.html
@@
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
+
+
+ Further Refinements: Thick Origami
+ Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
+
+
+ Guidance from Erik Demaine
+
+ From a discussion with Erik Demaine: double each crease into parallel offsets and open vertex regions as polygons
+ to prevent collisions. A uniform spacing works for a first pass, but for correctness the spacing between the doubled
+ creases should depend on how many layers lie between faces in the final folded state. I plan to estimate per‑crease
+ layer counts from an unfolded model and adjust offsets accordingly.
+
+
+ Citation: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”, Journal of Mechanisms and Robotics,
+ 8(3), June 2016, pp. 031003‑1–6. View paper
+
+
+
+
+ Thickened Crease Patterns
+
+
+
+
+
+ - Estimate: double each crease with a uniform offset and add regular polygons at intersections.
+ - Exact: compute sector‑aware offset polygons at vertices using incident crease angles.
+
+
+
+
+ How the Estimate Works
+
+Input: crease segments with mountain/valley labels; sheet size S; target thickness t
+offset = t / S (or a chosen fraction)
+for each crease c:
+ draw two lines parallel to c at ±offset
+for each vertex (intersection of original creases):
+ place a small regular polygon (e.g., octagon) centered at the vertex
+Output: doubled creases + vertex holes
+
+
+
+
+ How the Exact Method Works
+
+Input: crease lines; sheet size S; target thickness t
+offset = t / S
+for each crease c:
+ compute unit direction v and normals n1,n2
+ define two infinite offset lines at ±offset along n1/n2
+for each vertex:
+ collect incident creases; sort by angle into cyclic order
+ for each adjacent pair (i, j):
+ pick the offset side that lies inside the angular sector
+ intersect those two offset lines → one polygon vertex
+ connect all vertices in order → convex vertex polygon
+trim faces/creases by polygons as needed
+Output: doubled creases + exact vertex polygons
+
+
+
+
+ Next Step — Layer‑Aware Offsets
+ Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: estimate per‑crease layer counts and set per‑crease offset = k × thickness × layers(c), while keeping vertex polygons valid to avoid collisions.
+
+
* End PatchI'll insert the “Further Refinements: Thick Origami” subsection right after the Triple Gadget block within the Parametric Construction Kit section, matching the file's indentation and style, then check for any lint issues.
* Begin Patch
* Update File: /Users/saleem/MIT/classes/htmaa_25/week1.html
@@
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
+
+
+ Further Refinements: Thick Origami
+ Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
+
+
+ Guidance from Erik Demaine
+
+ From a discussion with Erik Demaine: double each crease into parallel offsets and open vertex regions as polygons
+ to prevent collisions. A uniform spacing works for a first pass, but for correctness the spacing between the doubled
+ creases should depend on how many layers lie between faces in the final folded state. I plan to estimate per‑crease
+ layer counts from an unfolded model and adjust offsets accordingly.
+
+
+ Citation: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”, Journal of Mechanisms and Robotics,
+ 8(3), June 2016, pp. 031003‑1–6. View paper
+
+
+
+
+ Thickened Crease Patterns
+
+
+
+
+
+ - Estimate: double each crease with a uniform offset and add regular polygons at intersections.
+ - Exact: compute sector‑aware offset polygons at vertices using incident crease angles.
+
+
+
+
+ How the Estimate Works
+
+Input: crease segments with mountain/valley labels; sheet size S; target thickness t
+offset = t / S (or a chosen fraction)
+for each crease c:
+ draw two lines parallel to c at ±offset
+for each vertex (intersection of original creases):
+ place a small regular polygon (e.g., octagon) centered at the vertex
+Output: doubled creases + vertex holes
+
+
+
+
+ How the Exact Method Works
+
+Input: crease lines; sheet size S; target thickness t
+offset = t / S
+for each crease c:
+ compute unit direction v and normals n1,n2
+ define two infinite offset lines at ±offset along n1/n2
+for each vertex:
+ collect incident creases; sort by angle into cyclic order
+ for each adjacent pair (i, j):
+ pick the offset side that lies inside the angular sector
+ intersect those two offset lines → one polygon vertex
+ connect all vertices in order → convex vertex polygon
+trim faces/creases by polygons as needed
+Output: doubled creases + exact vertex polygons
+
+
+
+
+ Next Step — Layer‑Aware Offsets
+ Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: estimate per‑crease layer counts and set per‑crease offset = k × thickness × layers(c), while keeping vertex polygons valid to avoid collisions.
+
+
* End PatchI'll insert the new thick-origami subsection right before the Parametric section closes, ensuring it appears after the Triple Gadget block. Then I'll run a quick lint check.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Further Refinements: Thick Origami
Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
Guidance from Erik Demaine
Summary: Based on a discussion with Erik Demaine, I explored thick‑origami methods where each crease is
doubled into parallel offsets and vertex regions are opened as polygons to prevent collisions. An initial
uniform spacing works, but to be truly correct, the spacing between doubled creases should depend on the
number of layers between faces in the final folded state. I will instrument the fold to estimate per‑crease
layer counts and adjust offsets accordingly.
Reference suggested by Erik Demaine: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”,
Journal of Mechanisms and Robotics, 8(3), June 2016, pp. 031003‑1–6.
View paper
Thickened Crease Patterns
Two approaches generated for my pattern:
- Estimate: double each crease with uniform offset and place regular polygons at intersections.
- Exact: compute sector‑aware offset polygons at vertices using the incident crease angles.
How the Estimate Works
Simple and robust; good for fabrication trials.
Input: crease segments with mountain/valley labels; sheet size S; target thickness t
offset = t / S (or a chosen fraction)
for each crease c:
draw two lines parallel to c at ±offset
for each vertex (intersection of original creases):
place a small regular polygon (e.g., octagon) centered at the vertex
Output: doubled creases + vertex holes
How the Exact Method Works
Sector‑aware vertex polygons following Ku–Demaine.
Input: crease lines; sheet size S; target thickness t
offset = t / S
for each crease c:
compute unit direction v and normals n1,n2
define two infinite offset lines at ±offset along n1/n2
for each vertex:
collect incident creases; sort by angle into cyclic order
for each adjacent pair (i, j):
pick the offset side that lies inside the angular sector
intersect those two offset lines → one polygon vertex
connect all vertices in order → convex vertex polygon
trim faces/creases by polygons as needed
Output: doubled creases + exact vertex polygons
Adjusting for Layer Counts (Next Step)
Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: instrument the folding to estimate per‑crease layer counts, then set per‑crease offset = k × thickness × layers(c), keeping polygons valid and avoiding collisions.
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Further Refinements: Thick Origami
Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
Guidance from Erik Demaine
From a discussion with Erik Demaine: double each crease into parallel offsets and open vertex regions as polygons
to prevent collisions. A uniform spacing works for a first pass, but for correctness the spacing between the doubled
creases should depend on how many layers lie between faces in the final folded state. I plan to estimate per‑crease
layer counts from an unfolded model and adjust offsets accordingly.
Citation: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”, Journal of Mechanisms and Robotics,
8(3), June 2016, pp. 031003‑1–6. View paper
Thickened Crease Patterns
- Estimate: double each crease with a uniform offset and add regular polygons at intersections.
- Exact: compute sector‑aware offset polygons at vertices using incident crease angles.
How the Estimate Works
Input: crease segments with mountain/valley labels; sheet size S; target thickness t
offset = t / S (or a chosen fraction)
for each crease c:
draw two lines parallel to c at ±offset
for each vertex (intersection of original creases):
place a small regular polygon (e.g., octagon) centered at the vertex
Output: doubled creases + vertex holes
How the Exact Method Works
Input: crease lines; sheet size S; target thickness t
offset = t / S
for each crease c:
compute unit direction v and normals n1,n2
define two infinite offset lines at ±offset along n1/n2
for each vertex:
collect incident creases; sort by angle into cyclic order
for each adjacent pair (i, j):
pick the offset side that lies inside the angular sector
intersect those two offset lines → one polygon vertex
connect all vertices in order → convex vertex polygon
trim faces/creases by polygons as needed
Output: doubled creases + exact vertex polygons
Next Step — Layer‑Aware Offsets
Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: estimate per‑crease layer counts and set per‑crease offset = k × thickness × layers(c), while keeping vertex polygons valid to avoid collisions.
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
First Success Assembly
Switched to thinner Amazon cardboard because the shop cardboard was too thick for the assembly pocket.
The Amazon box folded by hand fit perfectly and assembled smoothly. Three gadgets worked with the thinner
material. Rubber bands are just for compression — they assemble without them, though the bands make it
easier to keep them as one unit during insertion into the next gadget.
Quadruple Cut Strategy
Scaling up to quadruple cuts: sequential cuts, flips between sides, and opposite-side cutting strategies.
Double Gadget — Amazon Cardboard (No Support)
Three views of the double gadget assembled with Amazon cardboard, showing clean folds and proper fit.
Assembly Process with Support
Assembly sequence showing compression, support positioning, and insertion process for stable construction.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
AI-Assisted Thick Origami Conversion
A separate chat was used to convert a flat crease pattern into a thick‑origami version following Ku & Demaine.
The AI doubled each crease into parallel offsets and generated vertex polygons (estimate = regular polygons; exact = sector‑aware polygons) and explained how to map desired thickness by setting OFFSET_FRAC = thickness / sheet_size.
Done. I moved “Further Refinements: Thick Origami” to be a nested subsection under the Parametric Construction Kit assignment, placed directly after the Triple Gadget block. The standalone section was removed.
I'll locate the standalone “Further Refinements: Thick Origami” section and remove it, then move the existing thick-origami subsection into the “First Success Assembly” card right after the Triple Gadget block.
I'll remove the standalone “Further Refinements: Thick Origami” section near the top of week1.html, keeping the nested subsection under Parametric Construction Kit in place, then run a quick lint check.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Further Refinements: Thick Origami
Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
Guidance from Erik Demaine
From a discussion with Erik Demaine: double each crease into parallel offsets and open vertex regions as polygons
to prevent collisions. A uniform spacing works for a first pass, but for correctness the spacing between the doubled
creases should depend on how many layers lie between faces in the final folded state. I plan to estimate per‑crease
layer counts from an unfolded model and adjust offsets accordingly.
Citation: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”, Journal of Mechanisms and Robotics,
8(3), June 2016, pp. 031003‑1–6. View paper
Thickened Crease Patterns
- Estimate: double each crease with a uniform offset and add regular polygons at intersections.
- Exact: compute sector‑aware offset polygons at vertices using incident crease angles.
How the Estimate Works
Input: crease segments with mountain/valley labels; sheet size S; target thickness t
offset = t / S (or a chosen fraction)
for each crease c:
draw two lines parallel to c at ±offset
for each vertex (intersection of original creases):
place a small regular polygon (e.g., octagon) centered at the vertex
Output: doubled creases + vertex holes
How the Exact Method Works
Input: crease lines; sheet size S; target thickness t
offset = t / S
for each crease c:
compute unit direction v and normals n1,n2
define two infinite offset lines at ±offset along n1/n2
for each vertex:
collect incident creases; sort by angle into cyclic order
for each adjacent pair (i, j):
pick the offset side that lies inside the angular sector
intersect those two offset lines → one polygon vertex
connect all vertices in order → convex vertex polygon
trim faces/creases by polygons as needed
Output: doubled creases + exact vertex polygons
Next Step — Layer‑Aware Offsets
Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: estimate per‑crease layer counts and set per‑crease offset = k × thickness × layers(c), while keeping vertex polygons valid to avoid collisions.
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
First Success Assembly
Switched to thinner Amazon cardboard because the shop cardboard was too thick for the assembly pocket.
The Amazon box folded by hand fit perfectly and assembled smoothly. Three gadgets worked with the thinner
material. Rubber bands are just for compression — they assemble without them, though the bands make it
easier to keep them as one unit during insertion into the next gadget.
Quadruple Cut Strategy
Scaling up to quadruple cuts: sequential cuts, flips between sides, and opposite-side cutting strategies.
Double Gadget — Amazon Cardboard (No Support)
Three views of the double gadget assembled with Amazon cardboard, showing clean folds and proper fit.
Assembly Process with Support
Assembly sequence showing compression, support positioning, and insertion process for stable construction.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
AI-Assisted Thick Origami Conversion
A separate chat was used to convert a flat crease pattern into a thick‑origami version following Ku & Demaine.
The AI doubled each crease into parallel offsets and generated vertex polygons (estimate = regular polygons; exact = sector‑aware polygons) and explained how to map desired thickness by setting OFFSET_FRAC = thickness / sheet_size.
Done. I removed the standalone “Further Refinements: Thick Origami” section near the top and placed that content as a new subsection under the Parametric Construction Kit assignment, directly after “Triple Gadget — Final Assembly” within “First Success Assembly.”
I'll search the file for any remaining instances of the “Further Refinements: Thick Origami” heading to ensure there’s only one, correctly placed under the Parametric Construction Kit section, then remove any duplicates and fix placement if needed.
Placing the “Further Refinements: Thick Origami” content inside the “First Success Assembly” card directly after the Triple Gadget block, and removing the duplicate outside of it.
* Begin Patch
* Update File: /Users/saleem/MIT/classes/htmaa_25/week1.html
@@
-
+
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
-
-
+
+
Further Refinements: Thick Origami
Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
Guidance from Erik Demaine
From a discussion with Erik Demaine: double each crease into parallel offsets and open vertex regions as polygons
to prevent collisions. A uniform spacing works for a first pass, but for correctness the spacing between the doubled
creases should depend on how many layers lie between faces in the final folded state. I plan to estimate per‑crease
layer counts from an unfolded model and adjust offsets accordingly.
Citation: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”, Journal of Mechanisms and Robotics,
8(3), June 2016, pp. 031003‑1–6. View paper
Thickened Crease Patterns
- Estimate: double each crease with a uniform offset and add regular polygons at intersections.
- Exact: compute sector‑aware offset polygons at vertices using incident crease angles.
How the Estimate Works
Input: crease segments with mountain/valley labels; sheet size S; target thickness t
offset = t / S (or a chosen fraction)
for each crease c:
draw two lines parallel to c at ±offset
for each vertex (intersection of original creases):
place a small regular polygon (e.g., octagon) centered at the vertex
Output: doubled creases + vertex holes
How the Exact Method Works
Input: crease lines; sheet size S; target thickness t
offset = t / S
for each crease c:
compute unit direction v and normals n1,n2
define two infinite offset lines at ±offset along n1/n2
for each vertex:
collect incident creases; sort by angle into cyclic order
for each adjacent pair (i, j):
pick the offset side that lies inside the angular sector
intersect those two offset lines → one polygon vertex
connect all vertices in order → convex vertex polygon
trim faces/creases by polygons as needed
Output: doubled creases + exact vertex polygons
Next Step — Layer‑Aware Offsets
Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: estimate per‑crease layer counts and set per‑crease offset = k × thickness × layers(c), while keeping vertex polygons valid to avoid collisions.
-
+ All set. I removed the standalone “Further Refinements: Thick Origami” at the top and placed the thick‑origami subsection under the Parametric Construction Kit → First Success Assembly, directly after the Triple Gadget block. There should now be only one “Further Refinements” subsection in that location.
I'll move the "Further Refinements: Thick Origami" section to be at the same level as "First Success Assembly" (as a sibling h4), and place it right after the Triple Gadget image within the "First Success Assembly" card.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Further Refinements: Thick Origami
I'll move the "Further Refinements: Thick Origami" section to be at the same level as "First Success Assembly" by closing the First Success Assembly div and creating a new sibling section.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
First Success Assembly
Switched to thinner Amazon cardboard because the shop cardboard was too thick for the assembly pocket.
The Amazon box folded by hand fit perfectly and assembled smoothly. Three gadgets worked with the thinner
material. Rubber bands are just for compression — they assemble without them, though the bands make it
easier to keep them as one unit during insertion into the next gadget.
Quadruple Cut Strategy
Scaling up to quadruple cuts: sequential cuts, flips between sides, and opposite-side cutting strategies.
Double Gadget — Amazon Cardboard (No Support)
Three views of the double gadget assembled with Amazon cardboard, showing clean folds and proper fit.
Assembly Process with Support
Assembly sequence showing compression, support positioning, and insertion process for stable construction.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Further Refinements: Thick Origami
Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
Guidance from Erik Demaine
From a discussion with Erik Demaine: double each crease into parallel offsets and open vertex regions as polygons
to prevent collisions. A uniform spacing works for a first pass, but for correctness the spacing between the doubled
creases should depend on how many layers lie between faces in the final folded state. I plan to estimate per‑crease
layer counts from an unfolded model and adjust offsets accordingly.
Citation: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”, Journal of Mechanisms and Robotics,
8(3), June 2016, pp. 031003‑1–6. View paper
Thickened Crease Patterns
- Estimate: double each crease with a uniform offset and add regular polygons at intersections.
- Exact: compute sector‑aware offset polygons at vertices using incident crease angles.
How the Estimate Works
Input: crease segments with mountain/valley labels; sheet size S; target thickness t
offset = t / S (or a chosen fraction)
for each crease c:
draw two lines parallel to c at ±offset
for each vertex (intersection of original creases):
place a small regular polygon (e.g., octagon) centered at the vertex
Output: doubled creases + vertex holes
How the Exact Method Works
Input: crease lines; sheet size S; target thickness t
offset = t / S
for each crease c:
compute unit direction v and normals n1,n2
define two infinite offset lines at ±offset along n1/n2
for each vertex:
collect incident creases; sort by angle into cyclic order
for each adjacent pair (i, j):
pick the offset side that lies inside the angular sector
intersect those two offset lines → one polygon vertex
connect all vertices in order → convex vertex polygon
trim faces/creases by polygons as needed
Output: doubled creases + exact vertex polygons
Next Step — Layer‑Aware Offsets
Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: estimate per‑crease layer counts and set per‑crease offset = k × thickness × layers(c), while keeping vertex polygons valid to avoid collisions.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
AI-Assisted Thick Origami Conversion
A separate chat was used to convert a flat crease pattern into a thick‑origami version following Ku & Demaine.
The AI doubled each crease into parallel offsets and generated vertex polygons (estimate = regular polygons; exact = sector‑aware polygons) and explained how to map desired thickness by setting OFFSET_FRAC = thickness / sheet_size.
Perfect! I've moved the "Further Refinements: Thick Origami" section to be at the same level as "First Success Assembly" (both are now h4 headings within the Parametric Construction Kit section). The thick origami content is now positioned right after the Triple Gadget image, as a sibling section to "First Success Assembly" rather than nested within it.
I'll fix the Ethical AI section by separating the "AI-Assisted Thick Origami Conversion" from the "AI-Assisted Documentation and Link Integration" section, making them two distinct subsections.
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
First Success Assembly
Switched to thinner Amazon cardboard because the shop cardboard was too thick for the assembly pocket.
The Amazon box folded by hand fit perfectly and assembled smoothly. Three gadgets worked with the thinner
material. Rubber bands are just for compression — they assemble without them, though the bands make it
easier to keep them as one unit during insertion into the next gadget.
Quadruple Cut Strategy
Scaling up to quadruple cuts: sequential cuts, flips between sides, and opposite-side cutting strategies.
Double Gadget — Amazon Cardboard (No Support)
Three views of the double gadget assembled with Amazon cardboard, showing clean folds and proper fit.
Assembly Process with Support
Assembly sequence showing compression, support positioning, and insertion process for stable construction.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Further Refinements: Thick Origami
Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
Guidance from Erik Demaine
From a discussion with Erik Demaine: double each crease into parallel offsets and open vertex regions as polygons
to prevent collisions. A uniform spacing works for a first pass, but for correctness the spacing between the doubled
creases should depend on how many layers lie between faces in the final folded state. I plan to estimate per‑crease
layer counts from an unfolded model and adjust offsets accordingly.
Citation: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”, Journal of Mechanisms and Robotics,
8(3), June 2016, pp. 031003‑1–6. View paper
Thickened Crease Patterns
- Estimate: double each crease with a uniform offset and add regular polygons at intersections.
- Exact: compute sector‑aware offset polygons at vertices using incident crease angles.
How the Estimate Works
Input: crease segments with mountain/valley labels; sheet size S; target thickness t
offset = t / S (or a chosen fraction)
for each crease c:
draw two lines parallel to c at ±offset
for each vertex (intersection of original creases):
place a small regular polygon (e.g., octagon) centered at the vertex
Output: doubled creases + vertex holes
How the Exact Method Works
Input: crease lines; sheet size S; target thickness t
offset = t / S
for each crease c:
compute unit direction v and normals n1,n2
define two infinite offset lines at ±offset along n1/n2
for each vertex:
collect incident creases; sort by angle into cyclic order
for each adjacent pair (i, j):
pick the offset side that lies inside the angular sector
intersect those two offset lines → one polygon vertex
connect all vertices in order → convex vertex polygon
trim faces/creases by polygons as needed
Output: doubled creases + exact vertex polygons
Next Step — Layer‑Aware Offsets
Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: estimate per‑crease layer counts and set per‑crease offset = k × thickness × layers(c), while keeping vertex polygons valid to avoid collisions.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
AI-Assisted Thick Origami Conversion
A separate chat was used to convert a flat crease pattern into a thick‑origami version following Ku & Demaine.
The AI doubled each crease into parallel offsets and generated vertex polygons (estimate = regular polygons; exact = sector‑aware polygons) and explained how to map desired thickness by setting OFFSET_FRAC = thickness / sheet_size.
I need to clean up the duplicate links that got left behind. Let me remove the orphaned links:
Week 1 · HTMAA 2025 · Saleem A. Al Dajani
Week 1
Principles & Cutting · HTMAA 2025
CAD/CAM, Laser, Vinyl
This week focuses on the fundamentals of digital fabrication: computer-aided design (CAD), computer-aided manufacturing (CAM), laser cutting, and vinyl cutting. We'll learn the complete workflow from design to finished parts.
🎨 CAD design
⚡ Laser cutting
📄 Vinyl cutting
🔧 CAM toolpaths
This Week's Goals
-
Master CAD fundamentals
Parametric design, constraints, and best practices
-
Laser cutting workflow
Design → CAM → cut → test → iterate
-
Vinyl cutting techniques
Vector graphics, weeding, application
Assignments
-
Parametric construction kit
Design and fabricate a modular construction kit
-
Vinyl cutting project
Create a vinyl sticker or decal
-
Documentation
Document the complete design and fabrication process
-
Safety training
Complete laser cutter and vinyl cutter training
Tools & Materials
-
CAD software — Fusion 360, Onshape, or similar
-
Laser cutter — Epilog or similar CO2 laser
-
Vinyl cutter — Roland or similar plotter
-
Materials — Cardboard, acrylic, vinyl sheets
Training Documentation
Comprehensive training notes and media from laser cutter and vinyl cutter sessions.
Laser Cutter Training
Focusing Process
- Focus view follows the laser beam
- Use zoom in/zoom out to get better view
- Press Z, the number with checkmark shows how much to move
- Use focusing stick until it just hits the edge of the material
- Bed moves during focusing process
Cutting Process
- Control P to print, use max power with fast speed
- Go to universal program for cutting
- Turn on power for air compressor
- Press green button to start cutting
Vinyl Cutter Training
Software Setup
- Use Chrome browser
- Go to modsproject.org
- Select Program → Open Program
- Choose Roland vinyl cutter: cut program
- Load image (SVG or PNG format)
- Change dimensions with DPI settings
- For PNG: be careful with curves as it changes pixels
- Can invert to change where black areas are cut
- Set origin (defaults are usually fine)
- Blue lines = cut, red lines = rapids (knife lifts up)
Machine Setup
- Lever sets tension on drive wheels
- Clamp down at the end
- Wheel needs to be in white sections
- Press power (if just turned on)
- Select sheet and press enter
- Use arrow keys to move around
- Hold origin for new origin point
Connection & Starting
- Get device and connect properly
- Can change cut force but probably not necessary
- Send file to cutter
Weeding Process
- Weed early - pick out pieces you don't want
- Fold vinyl over itself, don't go straight up
- Use tweezers for precision
- Use transfer paper to lay front of vinyl on transfer paper
- Peel backing of vinyl off carefully
- Don't just plop things down to avoid air bubbles
- Use squeegee as you lay down to prevent air bubbles
- Consider sticker vs stencil applications
Useful Documentation
Additional resources and guides from Anthony Pennes for laser cutting, vinyl cutting, and image compression workflows.
Anthony's HTMA Guides
Comprehensive guides covering essential digital fabrication techniques, parameter optimization, and workflow best practices.
Image Compression Guide
Essential techniques for optimizing image file sizes, setting up batch processing tools, and maintaining repository efficiency.
📖 View Guide
Laser Cutting Guide
Complete laser cutting workflow including safety, parameter optimization, joint design, and troubleshooting techniques.
📖 View Guide
Vinyl Cutting Guide
Detailed vinyl cutting techniques, software setup, machine operation, and weeding processes for professional results.
📖 View Guide
Note: These guides were created by Anthony Pennes and are maintained as supplementary resources for the HTMAA course.
View original Slack message for context.
Laser Cutter Characterization Group Assignment
Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY
Machine Specifications
Available Lasers
- CO₂ Laser: 75W (large machine)
- CO₂ 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)
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
Finger joint - interlocking design for structural connections
Clearance Definition
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
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025
Preparation & Planning
Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.
Key Clarifications
Assignment Scope:
Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats:
DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements:
Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials:
Lab cardboard available, or personal materials (if safe to cut)
Technical Insights
Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)
Acknowledgments
Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.
Design Process
- Research and ideation for construction kit design
- Create parametric CAD model with adjustable parameters in Fusion 360
- Generate CAM toolpaths for laser cutting
- Test cut on cardboard to verify fit and function
- Iterate design based on test results
- Final cut on appropriate material
- Design and cut vinyl project (separate from construction kit)
Hand‑folded Prototype Assembly
I hand‑folded the crease pattern to validate the assembly. The parts do come together
when the folds are reasonably close to the intended lines. A second, refolded gadget
produced a noticeably cleaner assembly.
Single Gadget
Double Gadget
Assembly Detail
Full Pattern Failure
We tried cutting the full crease pattern on one side. It failed when layers with
opposite cuts overlapped and had to be push‑folded through during the final folding
step — the piece broke.
First Success Folded Single Gadget
First assembly of two gadgets. Folds were smooth after separating mountain and valley
cuts onto opposite sides to avoid breaking during push‑folds over multiple layers. The
shop cardboard was tight in the assembly pocket; thinner Amazon box cardboard folded by
hand fit better. Next step: make the laser‑cut pattern more exact.
Cut Strategy Videos
Left to right: clear mountain cut, flip and cut the opposite side, clear valley cut.
Mountain vs Valley Sides
Measurements confirming mountain vs valley sides.
First Gadget Assembly
Side profile and insertion step demonstrating clean folds without tearing.
Double Gadget Cut Variations
Exploring double‑part strategies: sequential cuts, flips between sides, and opposite‑side cuts.
Double Gadget — Rubber Band Assist
Temporary rubber band used to hold alignment while completing final folds.
First Success Assembly
Switched to thinner Amazon cardboard because the shop cardboard was too thick for the assembly pocket.
The Amazon box folded by hand fit perfectly and assembled smoothly. Three gadgets worked with the thinner
material. Rubber bands are just for compression — they assemble without them, though the bands make it
easier to keep them as one unit during insertion into the next gadget.
Quadruple Cut Strategy
Scaling up to quadruple cuts: sequential cuts, flips between sides, and opposite-side cutting strategies.
Double Gadget — Amazon Cardboard (No Support)
Three views of the double gadget assembled with Amazon cardboard, showing clean folds and proper fit.
Assembly Process with Support
Assembly sequence showing compression, support positioning, and insertion process for stable construction.
Triple Gadget — Final Assembly
The culmination: triple gadget assembly demonstrating successful scaling with Amazon cardboard and support techniques.
Further Refinements: Thick Origami
Applying thick‑origami concepts to avoid layer collisions and enable folding with real material thickness.
Guidance from Erik Demaine
From a discussion with Erik Demaine: double each crease into parallel offsets and open vertex regions as polygons
to prevent collisions. A uniform spacing works for a first pass, but for correctness the spacing between the doubled
creases should depend on how many layers lie between faces in the final folded state. I plan to estimate per‑crease
layer counts from an unfolded model and adjust offsets accordingly.
Citation: Jason S. Ku and Erik D. Demaine, “Folding Flat Crease Patterns With Thick Materials”, Journal of Mechanisms and Robotics,
8(3), June 2016, pp. 031003‑1–6. View paper
Thickened Crease Patterns
- Estimate: double each crease with a uniform offset and add regular polygons at intersections.
- Exact: compute sector‑aware offset polygons at vertices using incident crease angles.
How the Estimate Works
Input: crease segments with mountain/valley labels; sheet size S; target thickness t
offset = t / S (or a chosen fraction)
for each crease c:
draw two lines parallel to c at ±offset
for each vertex (intersection of original creases):
place a small regular polygon (e.g., octagon) centered at the vertex
Output: doubled creases + vertex holes
How the Exact Method Works
Input: crease lines; sheet size S; target thickness t
offset = t / S
for each crease c:
compute unit direction v and normals n1,n2
define two infinite offset lines at ±offset along n1/n2
for each vertex:
collect incident creases; sort by angle into cyclic order
for each adjacent pair (i, j):
pick the offset side that lies inside the angular sector
intersect those two offset lines → one polygon vertex
connect all vertices in order → convex vertex polygon
trim faces/creases by polygons as needed
Output: doubled creases + exact vertex polygons
Next Step — Layer‑Aware Offsets
Following Erik's advice, offsets should scale with the number of layers between faces in the folded state. Plan: estimate per‑crease layer counts and set per‑crease offset = k × thickness × layers(c), while keeping vertex polygons valid to avoid collisions.
Reflections & Learnings
Key insights and challenges encountered during this week.
Reflections will be added here as the week progresses...
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Katrina Li - Training Documentation
This week's training was well-documented by Katrina Li, thank you!
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Personal Notes - Laser Cutter Characterization
I took notes on the individual group assignment for characterizaing the laser cutter. :-)
Ethical AI Use
Transparent documentation of AI assistance used in this week's work, following course guidelines for ethical AI usage.
AI-Assisted Web Development in Cursor IDE
This week's webpage development, training documentation, and assignment preparation were assisted by Cursor AI.
The AI helped with HTML/CSS implementation, content organization, and structuring technical documentation.
AI-Assisted Section Organization and Content Updates
Cursor AI assisted with organizing webpage sections, cleaning up HTML structure, and updating content for both week 0 and week 1 pages.
The AI helped with code refactoring, section reorganization, and maintaining consistent styling across pages.
AI-Assisted Documentation and Link Integration
Cursor AI assisted with adding Anthony's HTMA guides to the Week 1 page, creating a new "Useful Documentation" section,
and integrating external resource links with proper styling and organization.
AI-Assisted Thick Origami Conversion
A separate chat was used to convert a flat crease pattern into a thick‑origami version following Ku & Demaine.
The AI doubled each crease into parallel offsets and generated vertex polygons (estimate = regular polygons; exact = sector‑aware polygons) and explained how to map desired thickness by setting OFFSET_FRAC = thickness / sheet_size.
Perfect! I've separated the Ethical AI section into two distinct subsections:
1. "AI-Assisted Documentation and Link Integration" - Contains the description about adding Anthony's HTMA guides and the corresponding transcript links 2. "AI-Assisted Thick Origami Conversion" - Contains the description about the ChatGPT conversation for thick origami conversion and the chat transcript link
Both sections are now properly separated with their own descriptions and links.
