# Add week 0 link to index.html _Exported on 9/13/2025 at 08:25:57 EDT from Cursor (1.5.11)_ --- **User** i want to create a new page for week 0 and week 1 that is linked from index.html. index.html has a spot to link week 1, but I need a spot for week 0 added --- **Cursor** I'll help you create new pages for week 0 and week 1, and update the index.html to link to both. Let me first examine the current index.html to understand the structure and see where the week 1 link is located. Now I can see the structure. I need to create a todo list to track the tasks, then create the week 0 and week 1 pages, and update the index.html to include a link for week 0. I can see that week 1 is already linked in the weekly documentation section (line 104-107), but there's no week 0. Let me start by creating the week 0 page. I'll base it on the styling and structure from the index.html file. ```html Week 0 · HTMAA 2025 · Saleem A. Al Dajani
← Back to Home
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

Reflections & Notes

This section will be updated throughout the week with thoughts, learnings, and progress updates.

Notes will be added here as the week progresses...

``` Now let me create the week 1 page: ```html Week 1 · HTMAA 2025 · Saleem A. Al Dajani
← Back to Home
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

Project Gallery

Photos and documentation from this week's work.

Cardboard joint from construction kit Vinyl cutter training setup

Process Documentation

Step-by-step documentation of the design and fabrication process.

Design Process

  1. Research and ideation for construction kit design
  2. Create parametric CAD model with adjustable parameters
  3. Generate CAM toolpaths for laser cutting
  4. Test cut on cardboard to verify fit and function
  5. Iterate design based on test results
  6. Final cut on appropriate material

Reflections & Learnings

Key insights and challenges encountered during this week.

Reflections will be added here as the week progresses...

``` Now I need to update the index.html file to add a week 0 link and update the existing week links to point to the actual HTML files. Let me update the weekly documentation section: ```html HTMAA 2025 · Saleem A. Al Dajani
Saleem A. Al Dajani

Saleem A. Al Dajani

MIT CEE PhD @ AbuGoot and Gladyshev Labs
HTMAA 2025 · Making + AI for Aging & Longevity

Welcome

This is my home base for How to Make (Almost) Anything. I’m documenting weekly assignments, fabrication experiments, and a final project that bridges making with aging & health analytics.

🛠️ Digital fabrication 🧬 Bioprinting 📈 Sensing & ML 🎛️ Embedded systems
Start with Week 1 → Explore projects

Now

  • Final project directions
    (A) Bioprinting rejuvenated tissue to measure function/compatibility. (B) A multimodal aging biomarker device (face, voice, ECG/HR/SpO₂/VO₂ max; possibly EEG/fNIRS).
  • Focus this week
    Set up documentation workflow, safety training, shop access, and first toolchain tests (CAD → CAM → cut/print).
  • Local time
    Loading…

Weekly Documentation

Week 00 · Course introduction
Setup, safety, orientation
Week 01 · Principles & cutting
CAD/CAM, laser, vinyl
Week 02 · Electronics production
PCB milling, soldering
Week 03 · Embedded programming
MCUs, toolchains
Week 04 · 3D printing & scanning
Meshes, tolerances
Week 05 · Molding & casting
Elastomers, resins
Week 06 · Electronics design
KiCad, EDA
Week 07 · Inputs
Sensors & signals
Week 08 · Outputs
Actuators, drivers
Week 09 · Networking
BLE/Wi‑Fi, protocols
Week 10 · Machine Design
Mechanisms, teams
Week 11 · Wildcard
Special processes
Week 12–13 · Final project
Integrate & demo

Lab Links & Logistics

  • Class site — MAS.863
  • Home base — EDS 38‑501 (hours: Sun 1p–12a; Mon–Thu 9a–12a; Fri 9a–5p)
  • Safety & training — machine checkouts, PPE, material inventory
  • Workflow — design (CAD) → toolpaths (CAM) → fabricate → test → iterate → document

Bioprinting Rejuvenated Tissue

Print muscle‑like constructs, benchmark mechanical properties, and study compatibility (old↔young cell mixes). Outputs: jigs, perfusion, test rig, imaging + data.

molding & casting micro‑fluidics mechanical tests

Aging Biomarker Device

Collect face + voice + vitals (ECG/HR/SpO₂/VO₂max; maybe EEG/fNIRS) for edge inference + on‑device logging. Emphasis on open, reproducible sensing.

embedded signal processing privacy‑aware ML

Toolchain Starter Kit

Minimal templates for week docs (Markdown → HTML), BOM tables, parametric CAD files, and reproducible build recipes.

templates BOM parametric CAD

Scratchpad

  • Design doc: problem → constraints → experiments → results → risks → next steps.
  • Document failures first; post photos, tool settings, and source files weekly.
  • Target 1 new process/week (laser, PCB mill, composites, etc.).

Checklists

  • ✔️ Git repo + web hosting set up
  • ⬜ Shop safety & machine training
  • ⬜ BOM tracker + suppliers
  • ⬜ Sensor test harness (ECG/PPG)

Reading & Inspiration

Fabrication, sensing, and health tech; plus a few works‑in‑progress from my broader research.

Contact

sdajani [at] mit.edu · Google Scholar

Bio

I am a PhD student in the Department of Civil and Environmental Engineering at the Massachusetts Institute of Technology (MIT), with joint affiliations at Brigham and Women’s Hospital (BWH, part of Mass General Brigham) and Beth Israel Deaconess Medical Center (BIDMC, part of Beth Israel Lahey Health) at Harvard Medical School (HMS), where I am a member of the Abudayyeh-Gootenberg Lab and the Gladyshev Lab. I am also affiliated with the Mesoscale Nuclear Materials (MNM) Group in the Short Lab within the Department of Nuclear Science and Engineering at MIT. My research integrates the mechanics of materials under extreme conditions with machine learning to advance health, aging, and longevity science. I am committed to developing rigorous research skills, effective scientific communication, and interdisciplinary collaboration at the interface of science, engineering, and artificial intelligence.

Ethical AI Usage

Session transcripts where ChatGPT helped refine designs, code, and plans for this course. Dropping links under each week for now, we'll see how categorization evolves!

Week 1

Week 2

Documenting any use of AI for parametric construction kit assignment here!

``` Perfect! I've successfully completed all the tasks. Let me check for any linting errors in the files I created and modified: Excellent! I've successfully completed your request. Here's what I've accomplished: ## ✅ Tasks Completed 1. **Created `week0.html`** - A dedicated page for Week 0 with: - Course introduction and setup content - Consistent styling matching your index.html - Navigation links to other pages - Sections for assignments, resources, and reflections 2. **Created `week1.html`** - A dedicated page for Week 1 with: - Principles & cutting content (CAD/CAM, laser, vinyl) - Project gallery section that references your existing training images - Process documentation structure - Consistent styling and navigation 3. **Updated `index.html`** - Added the Week 0 link to the weekly documentation section: - Added "Week 00 · Course introduction" with description "Setup, safety, orientation" - Updated Week 1 link to point to `week1.html` instead of the anchor - Both weeks now link to their respective HTML files ## 🎯 Key Features - **Consistent Design**: All pages use the same dark theme and styling as your original index.html - **Navigation**: Each page has back links and navigation to other weeks - **Responsive**: Mobile-friendly design that works on all screen sizes - **Image Integration**: Week 1 page references your existing training images in the `week1/training/` folder - **Extensible**: Easy to add more weeks following the same pattern The pages are now ready to use! You can navigate between them using the links in the weekly documentation section of your index page, and each week page has its own content structure that you can customize as needed. --- **User** add the mirror images in week0 folder to the week0 page for final project sketch --- **Cursor** I'll add the mirror images from the week0 folder to the week0 page as a final project sketch section. Let me first check what images are available in the week0 folder and then update the page. Perfect! I can see there are two mirror images. Now I'll update the week0.html page to include a final project sketch section with these images. ```html Week 0 · HTMAA 2025 · Saleem A. Al Dajani
← Back to Home
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

Final Project Sketch

Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.

Final project sketch - Mirror concept 1 Final project sketch - Mirror concept 2

Reflections & Notes

This section will be updated throughout the week with thoughts, learnings, and progress updates.

Notes will be added here as the week progresses...

``` I need to add the CSS for the image gallery to the week0.html page since it's not currently defined. Let me add that: ```html Week 0 · HTMAA 2025 · Saleem A. Al Dajani
← Back to Home
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

Final Project Sketch

Initial concept sketches for the final project - exploring ideas for bioprinting rejuvenated tissue and aging biomarker devices.

Final project sketch - Mirror concept 1 Final project sketch - Mirror concept 2

Reflections & Notes

This section will be updated throughout the week with thoughts, learnings, and progress updates.

Notes will be added here as the week progresses...

``` Now let me check for any linting errors: Perfect! I've successfully added the mirror images from the week0 folder to the week0 page. Here's what I've done: ## ✅ Changes Made 1. **Added Final Project Sketch Section** - Created a new section in week0.html that displays the mirror images as initial concept sketches for your final project 2. **Added Image Gallery CSS** - Included the necessary CSS styling for the image gallery to ensure the images display properly with: - Responsive grid layout that adapts to different screen sizes - Rounded corners and borders matching your design theme - Proper spacing and alignment 3. **Image Integration** - Added both `mirror1.png` and `mirror2.png` from the week0 folder with descriptive alt text The images are now displayed in a clean, responsive gallery format that fits well with your existing design. The section is positioned before the "Reflections & Notes" section, making it a prominent part of your week 0 documentation where you can showcase your initial final project concepts. --- **User** could you add all the training images and videos to a new section in week1.html? refine the notes below then put them and add the videos and images (from their names) in the right spots Laser: Focus view follows lasers Zoom in zoom out Control P, use max power fast speed Go to universal program Focusing stick Press z, number with checkmark is how much we move Bed is moving Focusing stick—till it just hits the edge Turn on power for air compressor Green button to start Vinyl cutter: Use chrome Modsproject.org Program Open program Roland vinyl cutter: cut program Roughly top to bottom left to right Most are information Black and white images Svg and png Load image Change dimension with dpi PNG — is changing pixels so careful on curves Can invert to change where on black it cuts Set origin defaults usually chill Testing cuts usually not necessary Get device Connect 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 — press enter Can move around with arrow and hold origin for new origin Can change cut force but prob don’t need Blue lines cut, red are rapids which mean knife lifts up Send file Weed early — pick out pieces u don’t want Fold it over itself don’t go straight up sticker vs stencil With tweezer Use transfer paper to lay front of vinyl on transfer paper, then peel backing of vinyl off Don’t just plop things down bc air bubbles Use squeegee as you lay down to prevent air bubbles --- **Cursor** I'll add a comprehensive training section to week1.html with all the training images and videos, and organize your notes into a clear, structured format. Let me first check what training media files are available and then update the page. Perfect! Now I'll add a comprehensive training section to week1.html with all the media files and your refined notes organized by tool. ```html Week 1 · HTMAA 2025 · Saleem A. Al Dajani
← Back to Home
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

Cardboard joint from construction kit

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

Vinyl cutter training setup

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

Process Documentation

Step-by-step documentation of the design and fabrication process.

Design Process

  1. Research and ideation for construction kit design
  2. Create parametric CAD model with adjustable parameters
  3. Generate CAM toolpaths for laser cutting
  4. Test cut on cardboard to verify fit and function
  5. Iterate design based on test results
  6. Final cut on appropriate material

Reflections & Learnings

Key insights and challenges encountered during this week.

Reflections will be added here as the week progresses...

``` Let me check for any linting errors: Perfect! I've successfully added a comprehensive training section to week1.html with all the training media and your refined notes. Here's what I've accomplished: ## ✅ Training Section Added ### **Laser Cutter Training** - **Focusing Process**: Video (`lasercutter_focus.mp4`) with detailed notes about focus view, zoom controls, Z-axis movement, and focusing stick usage - **Cutting Process**: Video (`lasercutter_cutting.mp4`) with notes about printing (Ctrl+P), power settings, air compressor, and starting the cut - **Project Image**: Cardboard joint photo showing the construction kit result ### **Vinyl Cutter Training** - **Software Setup**: Detailed notes about using Chrome, modsproject.org, program selection, file formats (SVG/PNG), DPI settings, and line color meanings - **Machine Setup**: Video (`vinyl_cutter_setup.mp4`) with notes about tension settings, wheel positioning, power, and origin setting - **Connection & Starting**: Two videos (`vinylcutter_connect.mp4` and `vinylcutter_start.mp4`) covering device connection and file sending - **Weeding Process**: Video (`weeding.mp4`) with comprehensive notes about weeding techniques, transfer paper usage, and avoiding air bubbles - **Training Image**: Setup photo showing the vinyl cutter training environment ## 🎯 Key Features - **Organized Structure**: Clear sections for each tool with logical workflow progression - **Media Integration**: All videos and images properly embedded with responsive styling - **Refined Notes**: Your raw notes have been cleaned up, organized, and formatted for clarity - **Visual Hierarchy**: Color-coded headings and proper spacing for easy navigation - **Responsive Design**: Videos and images scale properly on different screen sizes The training section now serves as a comprehensive reference guide that you can use throughout the course, with both visual demonstrations (videos) and detailed written instructions for each step of the laser cutting and vinyl cutting processes. --- **User** refine and organize these notes into a laser cutter characterization group assignment section on the week 1 page week 1 group assignment notes 09/11/2025 co2 laser 75w (large) 60w (small), fiber laser at the back rate 500 pulses per inch (ppi) power 100% speed 30% (increase by 2.5% each) kerf measure deltas focus — cut at the focal length (white part of the stick) joint clearance and type? what? type: finger joint clearance: the size of the slot that is tight enough generally no good joints in cardboard --- **Cursor** I'll add a refined laser cutter characterization group assignment section to the week1.html page with your notes organized into a clear, structured format. ```html Week 1 · HTMAA 2025 · Saleem A. Al Dajani
← Back to Home
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

Cardboard joint from construction kit

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

Vinyl cutter training setup

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

Laser Cutter Characterization Group Assignment

Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment completed: September 11, 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

Process Documentation

Step-by-step documentation of the design and fabrication process.

Design Process

  1. Research and ideation for construction kit design
  2. Create parametric CAD model with adjustable parameters
  3. Generate CAM toolpaths for laser cutting
  4. Test cut on cardboard to verify fit and function
  5. Iterate design based on test results
  6. Final cut on appropriate material

Reflections & Learnings

Key insights and challenges encountered during this week.

Reflections will be added here as the week progresses...

``` Let me check for any linting errors: Perfect! I've successfully added a comprehensive Laser Cutter Characterization Group Assignment section to the week1.html page. Here's what I've accomplished: ## ✅ Laser Cutter Characterization Section Added ### **Organized Structure** - **Machine Specifications**: Clear breakdown of available lasers (75W CO₂, 60W CO₂, Fiber laser) and test parameters - **Focus & Positioning**: Detailed notes on focal length, kerf measurement, and focus accuracy - **Joint Design & Clearance**: Explanation of finger joints and clearance definitions - **Material Considerations**: Important notes about cardboard limitations with visual indicators - **Key Learnings**: Synthesized insights from the characterization process ### **Key Features** - **Professional Layout**: Clean, organized sections with color-coded headings and structured information - **Visual Hierarchy**: Different background colors and typography to distinguish between sections - **Technical Details**: All your raw notes refined and organized into logical categories - **Date Documentation**: Assignment completion date (September 11, 2025) clearly marked - **Actionable Insights**: Key learnings section that synthesizes the practical knowledge gained ### **Content Refinements** - Expanded technical explanations (e.g., "finger joint - interlocking design for structural connections") - Added context for technical terms (e.g., "kerf measurement essential for compensating cut width") - Highlighted important limitations (cardboard joint quality issues) - Structured the systematic testing approach (2.5% speed increments) The section now serves as a comprehensive reference for laser cutter characterization methodology and results, making it easy to understand the testing process and apply the learnings to future projects. --- **User** refine these chats into the construction kit individual assignment section in week 1 under preparation, thanking Erik Demaine and Anthony Pennes Saleem Al Dajani — 9/10/25, 6:50 PM Got into how to make (almost) anything! Quick question, if you were CADing a crease pattern to be vinyl cut onto cardboard, how think would you make the creases? Erik Demaine — 9/10/25, 7:00 PM Zero? Vinyl cutter generally wants zero thickness lines. Saleem Al Dajani — 9/10/25, 7:01 PM Got it, still learning how to do it For mountain vs valley, would you just cut them onto opposite sides if the cardboard? Or how do you differentiate between mountain and valley in the cut itself? I’m trying to do the shuriken assemblies as the parametric construction kit with vinyl cutter homework 🙂 Erik Demaine — 9/10/25, 11:40 PM If it's thick, yeah, you'd want opposite sides. If it's thin you might be able to get away with all cuts on same side... Saleem Aldajani 8:56 PM Looked into vinyl cutting creases patterns, should be doable with zero thickness lines in the CAD Saleem Aldajani 2:06 PM For the vinyl cutter, do we need the final designs in .DXF? (edited) Anthony Pennes 2:07 PM No we'll want a black and white image for that 2:07 Dxf for the laser though Saleem Aldajani 2:08 PM .PNG or what image format? Is it ok to design it in inkscape for the crease pattern? Not sure what I get from fusion that I can’t do in inkscape 2:09 Also for black and white, how to differentiate between cut lines (borders) and fold lines? Anthony Pennes 2:26 PM PNG or SVG for the image in the vinyl cutter. The laser cut part has to be done in fusion, again the real goal here is cad familiarity. What's going in the vinyl cutter? I don't think you really could fold vinyl very well. You could maybe do those as dashed lines but it'll be difficult given the software Saleem Aldajani 2:36 PM Got it, let’s discuss more at office hours 2:39 I thought the point of the assignment was to make the construction kit with vinyl cutter cuts, a bit confused but it’s ok I’ll just focus on designing now and figure out the machines in the shop later, I’ll do my best to be ready to export whatever we need Anthony Pennes 2:40 PM No it's to make a construction kit with the laser cutter and vinyl cut something else Saleem Aldajani 3:02 PM Got it 3:03 Do we need to use cardboard for the construction kit? Or do we have any other options? I mostly remember laser cutting acrylic and never used a vinyl cutter before Anthony Pennes 3:04 PM You can use our cardboard or if you pay for other materials (that are safe to cut) you could use those as well. :+1: 1 --- **Cursor** I'll refine these chat conversations into a preparation section for the Parametric Construction Kit Individual Assignment, organizing the key insights and thanking Erik Demaine and Anthony Pennes for their guidance. ```html Week 1 · HTMAA 2025 · Saleem A. Al Dajani
← Back to Home
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

Cardboard joint from construction kit

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

Vinyl cutter training setup

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

Laser Cutter Characterization Group Assignment

Systematic testing and documentation of laser cutter parameters for optimal cutting performance. Assignment started: September 11, 2025 Assignment completed: MM DD, YYYY

Machine Specifications

Available Lasers

  • CO₂ Laser: 75W (large machine)
  • CO₂ Laser: 60W (small machine)
  • Fiber Laser: Back of lab

Test Parameters

  • Rate: 500 pulses per inch (PPI)
  • Power: 100%
  • Speed: 30% (increased by 2.5% each test)

Focus & Positioning

  • Focus Point: Cut at the focal length (white part of the focusing stick)
  • Kerf Measurement: Measure deltas between intended and actual cut dimensions
  • Focus Accuracy: Critical for achieving clean, precise cuts

Joint Design & Clearance

Joint Type

Finger joint - interlocking design for structural connections

Clearance Definition

Size of the slot that provides tight enough fit for assembly

Material Considerations

Cardboard Limitations: Generally produces no good joints due to material properties and laser cutting characteristics

Material choice significantly impacts joint quality and assembly precision

Key Learnings

  • Speed increment of 2.5% provides systematic testing progression
  • Focus accuracy is critical for dimensional precision
  • Kerf measurement essential for compensating cut width in designs
  • Material selection directly impacts joint quality and assembly success
  • Systematic parameter testing reveals optimal settings for different materials

Parametric Construction Kit Individual Assignment

Design and fabricate a modular construction kit using laser cutting and vinyl cutting techniques. Assignment started: September 10, 2025

Preparation & Planning

Initial research and clarification discussions with instructors and classmates to understand assignment requirements and technical constraints.

Key Clarifications

Assignment Scope: Construction kit using laser cutter + separate vinyl cutting project (not crease patterns on cardboard)
File Formats: DXF for laser cutting, PNG/SVG for vinyl cutting
CAD Requirements: Must use Fusion 360 for laser cutting to develop CAD familiarity
Materials: Lab cardboard available, or personal materials (if safe to cut)

Technical Insights

Vinyl Cutting: Zero thickness lines for crease patterns, black and white images for cutting
Mountain vs Valley Folds: Opposite sides for thick materials, same side possible for thin materials
Design Differentiation: Dashed lines for fold lines, solid lines for cuts (though challenging in software)

Acknowledgments

Special thanks to Erik Demaine for guidance on vinyl cutting crease patterns and fold differentiation techniques, and Anthony Pennes for clarifying assignment requirements, file formats, and material options. Their expertise was invaluable in understanding the technical constraints and design possibilities for this project.

Design Process

  1. Research and ideation for construction kit design
  2. Create parametric CAD model with adjustable parameters in Fusion 360
  3. Generate CAM toolpaths for laser cutting
  4. Test cut on cardboard to verify fit and function
  5. Iterate design based on test results
  6. Final cut on appropriate material
  7. Design and cut vinyl project (separate from construction kit)

Reflections & Learnings

Key insights and challenges encountered during this week.

Reflections will be added here as the week progresses...

``` Let me check for any linting errors: Perfect! I've successfully refined the chat conversations into a comprehensive Preparation & Planning section for the Parametric Construction Kit Individual Assignment. Here's what I've accomplished: ## ✅ Preparation Section Added ### **Key Clarifications** - **Assignment Scope**: Clearly distinguished between construction kit (laser cutting) and separate vinyl project - **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** - **Erik Demaine**: Thanked for guidance on vinyl cutting crease patterns and fold differentiation techniques - **Anthony Pennes**: Thanked for clarifying assignment requirements, file formats, and material options - Professional acknowledgment highlighting their expertise and invaluable contributions ### **Enhanced Design Process** - Updated the design process to include Fusion 360 requirement - Added separate vinyl project as a distinct step - Maintained the systematic approach while incorporating the clarifications The section now serves as a comprehensive reference for the assignment preparation, documenting the learning process and giving proper credit to the instructors who provided guidance. The information is well-organized and visually appealing, making it easy to reference during the project work.