Week 1 Results Section Development
Cursor AI Transcript · HTMAA 2025
Table of Contents
Overview
Complete transcript of Cursor AI assistance for creating the comprehensive Results section with kerf and clearance analysis
Full Conversation
I'll help you update the week1.html file to add a new "Results" subsection to the group assignment section with the kerf and clearance data. Let me first examine the current structure and the Excel file to understand what we're working with.
Let me search for the group assignment section in the HTML file to understand its current structure:
Now let me read the group assignment section to see its current structure:
Now let me create a todo list to track the tasks and then add the Results subsection to the group assignment section:
Now I'll add the Results subsection to the group assignment section. Based on the data from the Google Sheets, I can see there are two main data tables - one for kerf measurements and one for clearance measurements. Let me add this section right before the closing of the group assignment 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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now let me update the todo list to mark the completed tasks and check for any linting errors:
Perfect! I've successfully updated the week1.html file with a comprehensive "Results" subsection in the Laser Cutter Characterization Group Assignment section. Here's what I've added:
✅ Results Section Features:
1. Google Sheets Integration
2. Kerf Analysis Table
3. Clearance Analysis Table
4. Key Findings Summary
5. Aesthetic Design
The section is now complete with no placeholders and provides a comprehensive view of the laser cutter characterization results, making the data easily accessible and professionally presented. The Google Sheets link allows for interactive data exploration while the HTML tables provide immediate access to the key findings.
I'll help you add the measurement images and improve the explanation in the kerf and clearance section. Let me first check if those image files exist and then update the section with the images and clearer methodology explanation.
Great! I found all three images. Now let me update the Results section to add a "Methods" subsection with the images and clearer explanation of the measurement process.
Now let me add the Methods subsection right after the Google Sheets section and before the data tables:
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now let me update the todo list to mark the completed tasks and check for any linting errors:
Perfect! I've successfully added a comprehensive "Measurement Methods" subsection to the Results section. Here's what I've implemented:
✅ New Methods Section Features:
1. Visual Documentation
2. Clear Methodology Explanation
3. Professional Layout
4. Enhanced User Experience
The Results section now provides a complete picture: methodology with visual documentation, followed by the comprehensive data tables, and finally the key findings summary. This makes the kerf and clearance analysis much more accessible and professional.
I'll add the kerf.png and clearance.png diagrams to their respective sections with captions and downloadable links. Let me first check if the keynote and PDF files exist, then add the diagrams.
Great! I found the PDF file. Let me also check for any keynote files in the kerfandclearance directory:
Perfect! I can see the kerf.png and clearance.png files, plus the PDF. Now let me add the diagrams to their respective sections with captions and download links.
Now let me add the kerf diagram before the Kerf Analysis Results 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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now let me add the clearance diagram before the Clearance Analysis Results 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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now let me update the todo list and check for any linting errors:
Perfect! I've successfully added both concept diagrams to the Results section. Here's what I've implemented:
✅ New Diagram Sections Added:
1. Kerf Concept Diagram
kerf.png showing laser cut width measurement2. Clearance Concept Diagram
clearance.png showing peg and hole fit analysis3. Professional Presentation
4. Enhanced User Experience
The Results section now has a complete flow: 1. Google Sheets Integration - Interactive data access 2. Measurement Methods - Process documentation with photos 3. Kerf Concept Diagram - Visual explanation of kerf 4. Kerf Analysis Results - Data table 5. Clearance Concept Diagram - Visual explanation of clearance 6. Clearance Analysis Results - Data table 7. Key Findings - Summary statistics
This creates a comprehensive, professional presentation of the laser cutter characterization results with both visual and numerical data.
I'll update both diagram sections to add the keynote file link, update the PDF button text, and add a download link for the Excel data tables. Let me first check if there's a keynote file and then make the updates.
I can see the PDF and Excel files exist, but no keynote file. Let me update both diagram sections to improve the download links as requested:
Now let me update the kerf diagram section first:
Let me be more specific and target just the kerf diagram section by including more context:
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now let me update the clearance diagram 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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
I'll add the keynote file link to both diagram sections. Let me update the todo list and add the keynote download links.
Now let me add the keynote file link to the kerf diagram section:
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tablesLet me be more specific and target just the kerf diagram section by including more context:
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now let me add the keynote file link to the clearance diagram 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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now let me update the todo list and check for any linting errors:
Perfect! I've successfully updated both diagram sections with all the requested download links. Here's what I've implemented:
✅ Updated Download Links for Both Diagram Sections:
1. Kerf Concept Diagram Section
kerfandclearance.pdf with updated button textkerfandclearance.xlsx with Excel datakerfandclearance.key for the presentation file2. Clearance Concept Diagram Section
kerfandclearance.pdf with updated button textkerfandclearance.xlsx with Excel datakerfandclearance.key for the presentation file3. Professional Button Design
4. Enhanced User Experience
Both diagram sections now provide comprehensive access to all related files:
The download links are properly styled and integrated into the existing design, maintaining consistency with the rest of the page while providing easy access to all supporting materials.
I'll create aesthetically pleasing tables of contents for both week0.html and week1.html that provide clear navigation without cluttering the pages. Let me first examine the current structure of both files to understand what sections need to be included.
Now let me search for the main section headings in both files to understand their structure:
Now let me create a todo list and start adding table of contents to both files:
Let me start with week0.html. I'll add a table of contents right after the hero section:
Let me find where the hero section ends to add the table of contents:
Perfect! I'll add the table of contents right after the hero section (line 143) and before the first card section. Let me add it:
Table of Contents
Course Content
Project & Documentation
Let me be more specific with the context:
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Now I need to add the corresponding IDs to the section headings in week0.html. Let me add them:
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Now let me update the todo list and move on to week1.html:
Now let me add the table of contents to week1.html. First, let me find where to place it:
Perfect! I'll add the table of contents right after the hero section (line 145) and before the first card section. Let me add it:
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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now I need to add the corresponding IDs to the section headings in week1.html. Let me add them:
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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the 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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now let me update the todo list and check for any linting errors:
Perfect! I've successfully added aesthetically pleasing tables of contents to both week0.html and week1.html. Here's what I've implemented:
✅ Table of Contents Features:
Week 0 Table of Contents
Week 1 Table of Contents
Aesthetic Design Features
Navigation Features
Technical Implementation
Both tables of contents provide clear navigation without cluttering the pages, making it easy for users to quickly jump to any section they're interested in. The design is consistent with the existing aesthetic while being functional and visually appealing.
I'll add Camron Blackburn to the contributions section in both week0.html and week1.html, thanking her for reviewing the website and suggesting the table of contents.
Let me first add Camron to week0.html contributions section:
Now let me add Camron's contribution to week0.html:
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Camron Blackburn - Website Review & Table of Contents Suggestion
Camron reviewed the website and provided valuable feedback on navigation and user experience. She suggested implementing a table of contents to make it easier for visitors to navigate through the different sections of the weekly documentation. This suggestion led to the creation of the sleek, organized table of contents that now appears on both Week 0 and Week 1 pages, significantly improving the overall user experience and accessibility of the documentation.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Now let me add Camron to week1.html contributions section:
Let me add Camron's contribution to week1.html:
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
Table of Contents
Training & Documentation
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: September 16, 2025
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
Results
Comprehensive analysis of kerf and clearance measurements from systematic laser cutter testing.
Interactive Data Analysis
View and interact with the complete dataset in Google Sheets:
Open in Google Sheets
|
Data includes kerf measurements, clearance analysis, and statistical calculations
Measurement Methods
Systematic measurement approach for characterizing laser cutter kerf and joint clearance using precision calipers.
Peg and hole measurement setup
Top measurement view
Bottom measurement view
Measurement Protocol
- Kerf Analysis: Three measurements were taken for each prescribed cut dimension on the joint gadget during laser cutter training
- Clearance Analysis: Three measurements were taken for both hole and peg dimensions
- Clearance Calculation: Clearance = Hole Size - Peg Size (negative values indicate interference fit)
- Statistical Analysis: Averages and standard deviations calculated for precision assessment
Kerf Concept Diagram
Kerf Definition: The width of material removed by the laser beam during cutting.
Measured as the difference between prescribed cut dimensions and actual cut dimensions.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Kerf Analysis Results
Prescribed Cut (in)
Actual Cut #1 (in)
Actual Cut #2 (in)
Actual Cut #3 (in)
Average (in)
Std Dev (in)
Avg Kerf (in)
0.136
0.142
0.1405
0.1445
0.1423
0.0020
0.0032
0.137
0.142
0.1475
0.149
0.1462
0.0037
0.0046
0.138
0.148
0.1495
0.147
0.1482
0.0013
0.0051
0.139
0.146
0.146
0.1475
0.1465
0.0009
0.0038
0.143
0.155
0.1555
0.1545
0.1550
0.0005
0.0060
0.144
0.1535
0.153
0.15
0.1522
0.0019
0.0041
0.152
0.163
0.1655
0.165
0.1645
0.0013
0.0063
0.153
0.166
0.169
0.168
0.1677
0.0015
0.0073
Clearance Concept Diagram
Clearance Definition: The dimensional difference between hole and peg sizes.
Negative values indicate interference fit (hole smaller than peg), while positive values indicate clearance fit.
Download Diagram PDF
Download Data Tables
Download Keynote
|
Complete analysis diagrams and data tables
Clearance Analysis Results
Measurement
Sample #1 (in)
Sample #2 (in)
Sample #3 (in)
Average (in)
Std Dev (in)
Peg Size
0.1505
0.1535
0.1505
0.1515
0.0017
Hole Size
0.156
0.1575
0.1545
0.1560
0.0015
Clearance
-0.0055
-0.004
-0.004
-0.0045
0.0009
Key Findings
Average Kerf
0.0049 inches (4.9 thousandths)
Average Clearance
-0.0045 inches (interference fit)
Kerf Std Dev
±0.0017 inches (high precision)
Clearance Std Dev
±0.0009 inches (very consistent)
Parametric Construction Kit Individual Assignment: 3D Parametric Design
Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025. Assignment completed: September 15, 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.
Vinyl Cutter Individual Assignment: 2D Parametric Design
Design and cut vinyl stickers and stencils using the vinyl cutter. Assignment started: September 15, 2025 Assignment completed: September 15, 2025
Project Overview
Planned to vinyl cut lab logo stickers at first. Collected .png or .svg for each logo for the vinyl cutter software, and executing the complete workflow from cutting to final application. I hope to come back to the lab logos when there is less traffic on the vinyl cutter, I was more excited to see the fine detail of the vinyl cutter with the 2D parametric design at first!
Lab Logo Designs
Gladyshev Lab Logo
Abugoot Logo Design
2D Parametric Sticker Design
Used a parametric sticker design that can be infinitely customized through an interactive web application.
The design demonstrates the power of parametric modeling in creating personalized vinyl stickers with
adjustable parameters for size, complexity, and visual elements. The assignment demonstrated both successful execution and troubleshooting when equipment issues arose.
Interactive Design Generator
This web-based generator was created as a final project in 6.5310 last semester and was used to download
a PNG of the default design shown above. Generate unlimited variations of this parametric design by
adjusting parameters in real-time to create custom stickers for any application.
🎨 Generate Custom Designs
Successful Cut and Transfer
Complete workflow from vinyl cutting through final sticker application, demonstrating the full process from design to finished product.
Vinyl Cutting Process
Vinyl cutter in action, cutting the Gladyshev Lab logo design with precise blade control and proper tension settings.
Completed Vinyl Cut
Clean vinyl cut showing precise cuts with proper registration and no tearing or incomplete cuts.
Weeding Process
Systematic weeding process: starting from center, progressing through unwanted sections, and finishing with clean weeded vinyl ready for transfer.
Transfer Paper Application
Transfer paper application process: carefully applying transfer paper to hold vinyl design, then removing it to prepare for final application.
Vinyl Application Process
Final application steps: positioning vinyl on target surface, using tweezers for precise removal of the broken thin vinyl strip, and achieving clean final application.
Completed Takehome Sticker
Final result: applied laptop vinyl sticker and takehome vinyl sticker ready for use, demonstrating successful completion of the vinyl cutting workflow.
Motor Failure
Encountered and resolved a motor failure during the vinyl cutting process, demonstrating troubleshooting skills and equipment maintenance knowledge.
Motor Error Display
Vinyl cutter displaying motor error, indicating a mechanical issue that prevented normal operation.
Roll Failure Analysis
Side-by-side comparison showing the vinyl roll before and after the failure. The roll ran out of material and then fell, causing the vinyl to kink under the cutting wheel.
Troubleshooting Solution
Simple fix process:
- Turn off the vinyl cutter
- Remove tape from the fallen roll to get the weight off
- Readjust vinyl in between the wheels to ensure proper tension
- Start again (or load a new roll if needed)
This common issue occurs when the vinyl roll runs out or becomes misaligned, causing the cutting mechanism to fail. The solution involves proper material handling and machine setup.
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!
Camron Blackburn - Website Review & Table of Contents Suggestion
Camron reviewed the website and provided valuable feedback on navigation and user experience. She suggested implementing a table of contents to make it easier for visitors to navigate through the different sections of the weekly documentation. This suggestion led to the creation of the sleek, organized table of contents that now appears on both Week 0 and Week 1 pages, significantly improving the overall user experience and accessibility of the documentation.
Mariam Fitaihi - Photos and Videos
Photos and videos of this week's training were taken by Mariam Fitaihi, thank you!
Erik Demaine - Thick Origami Guidance
Erik reviewed my approach to folding thick materials and suggested using the Ku & Demaine thick‑origami method. He pointed me to the paper and
emphasized that doubled creases should be spaced according to the number of layers between faces in the final fold. This feedback led me to implement
two variants (estimate and exact) of thickened crease patterns and to plan a next step for layer‑aware offsets.
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.
AI-Assisted Repository Management and Content Organization
Cursor AI assisted with repository size management by breaking down large commits into smaller, manageable chunks under 10MB each.
The AI helped organize media files into logical commits, added the Vinyl Cutter Individual Assignment section with proper styling and image sizing,
and provided guidance on git workflow optimization to work within platform size limits.
AI-Assisted Vinyl Cutter Assignment Documentation
Cursor AI assisted with updating the vinyl cutter individual assignment section with comprehensive documentation including
successful cut and transfer workflow, motor failure troubleshooting, and 2D parametric design integration. The AI helped
structure the content with proper media organization, descriptive captions, and consistent styling throughout the section.
Now let me update the todo list and check for any linting errors:
I'll move Camron Blackburn's contribution from week0.html to week1.html and remove it from week0.html.
First, let me remove Camron's contribution from week0.html:
Week 0 · HTMAA 2025 · Saleem A. Al Dajani
Week 0
Course Introduction & Setup · HTMAA 2025
Course Introduction
Welcome to How to Make (Almost) Anything! This week focuses on course orientation, safety training, and setting up the foundation for the semester ahead.
📚 Course orientation
🛡️ Safety training
⚙️ Tool setup
📋 Documentation
This Week's Goals
-
Complete safety training
Shop orientation, machine checkouts, PPE requirements
-
Set up documentation workflow
Git repo, web hosting, weekly documentation structure
-
Explore the lab space
Familiarize with tools, materials, and workflow
Assignments
-
Course agreement
Review and sign the course agreement
-
Safety training
Complete all required safety modules
-
Documentation setup
Create personal documentation site
-
Final project proposal
Initial ideas and research direction
Resources
-
Course website — MAS.863
-
Lab location — EDS 38‑501
-
Safety protocols — Machine checkouts, PPE requirements
-
Documentation examples — Past student projects for reference
Table of Contents
Course Content
Project & Documentation
Final Project Sketch
Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.
Reflections & Notes
Early ideation and planning takeaways for the final project and weekly milestones.
Concepts Under Consideration
-
Mirror concept — reference video
- Motorized tilt; potential face recognition
- On‑board camera connected to the internet; model outputs shown on screen
- Voice capture for age; display results and, if possible, text‑to‑speech
- Integrate conversational layer (e.g., “Mirror, mirror on the wall…” for interpreting metrics)
-
Rejuvenated tissue idea — to define scope and feasibility (TBD)
-
Multimodal aging biomarker idea — sensor fusion + ML pipeline (TBD)
-
Dome idea — structural/form exploration (TBD)
-
Shuriken idea — mechanism/prototyping study (TBD)
Planning & Course Requirements
- Design as modular subsystems so components can be swapped or removed and still pass
- Fabricate custom parts and build my own electronics; target at least two PCBs
- Sequence work so each week contributes a testable piece toward the final build
Contributions
Acknowledgements for the help I received this week from my classmates and instructors.
Alfonso Parra Rubio - Fusion Office Hours
Thank you to Alfonso for providing helpful Fusion office hours and guidance on CAD modeling techniques.
Dan Gilbert - CBA Shop
Thank you to Dan Gilbert for assistance with the CBA shop facilities and equipment access.
Tolga Durak - SHED Bioprinter Access Discussion
Had extensive discussions with Tolga Durak about accessing the SHED bioprinter for potential final project work. Tolga provided detailed guidance on the BRR (Biological Research Registration) process through MIT's CAB/ESCRO committee, including requirements for MIT PI involvement, research proposal structure, and timeline considerations. He explained that the bioprinter is currently limited to approved research projects due to existing commitments, and that any access would need to be scheduled around three ongoing research projects. Prof. Gershenfeld agreed to serve as the MIT PI for the proposal, and I'm working through the BRR forms to submit the necessary documentation for committee review.
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 was assisted by Cursor AI to create the initial page structure, styling, and content organization.
The AI helped with HTML/CSS implementation and responsive design patterns.
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.
Download Options
For the complete technical details and full conversation transcript: