This week I experimented with laser cutting as a way to quickly prototype structural ideas. I started with simple 2D sketches and translated them into cut patterns, testing different thicknesses and joint details. The process allowed me to explore how flat sheets could transform into three-dimensional structures through slot connections and flexible hinges. By assembling multiple modules, I began to see how geometric repetition could create more complex mechanical forms. These early experiments gave me a better understanding of material tolerances, accuracy, and structural behavior, which will be essential for building future moving prototypes.

Process

I prepared digital drawings for the laser cutter, experimenting with different kerf settings, material thicknesses, and joint designs. Through cutting and assembling, I observed how small variations in the slot dimensions affected the overall stability. The workflow was highly iterative: sketch → cut → assemble → adjust. This hands-on cycle helped me quickly refine the geometry and understand the structural limits of the material.

Gallery

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1. First round of laser-cut test pieces, checking kerf and slot fit.
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2. Variations of joint geometry laid out for comparison.
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3. Assembled modules starting to form a three-dimensional structure.
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4. Short animation showing the folding and flexing behavior of the pattern.
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5. Another motion test focusing on how repeated units move together.
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6. Close-up of the joints and edge quality after cutting.
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7. Exploring how modules can tile and connect into a larger surface.
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8. Testing structural stability by standing the assembly vertically.
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9. Final configuration for this round of experiments, combining several modules.
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10. Animation documenting how the assembled piece can move and bend.

Vinyl Cutter

For this part of the assignment, I cut the silhouettes of my favorite anime characters — Gon and Killua from HUNTER × HUNTER. This experiment was not only a technical test of the vinyl cutter but also a way to bring in a more personal and playful element to the fabrication process.

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11. Vector outlines prepared for cutting on the vinyl cutter.
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12. Cutting process captured as a short looped animation.
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13. Freshly cut character silhouettes before weeding.
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14. Final vinyl stickers applied to a notebook as a small personal detail.