Computer-Controlled Cutting

Assignment 02 · Laser & Vinyl Cutting

Overview

This week's assignment focused on two computer-controlled cutting technologies: laser cutting for structural assembly and vinyl cutting for graphic applications. I designed a parametric construction kit that assembles into a cubist dog and created a vinyl decal of the Delhi skyline.

Tools Used

  • CAD: Autodesk Fusion 360
  • Laser Cutter: Universal Laser Systems (ULS) CO₂ Laser
  • Vinyl Cutter: Roland Vinyl Plotter
  • Materials: Corrugated cardboard, adhesive vinyl
Complete project showcase
Completed projects: Cubist dog assembly and Delhi skyline panel

01 · Parametric Joinery: Cubist Dog

I modeled a family of lego-like plates in Autodesk Fusion and tuned slot geometry so that laser-cut parts friction-fit into a rigid, self-supporting structure. The pieces assemble into a playful, cubist dog while maintaining repeatable, orthogonal joins.

Design Process

When designing press-fit parts, one issue is that perfectly square slot edges can make it hard to insert pieces without damaging the corners. A simple solution is to add a tiny finishing cut that slightly widens the ends of the slots, giving the material room to slide in cleanly.

Parametric Design: By defining key dimensions as parameters (like thickness, slot width, or spacing) and applying constraints (such as symmetry, equal, and coincident), I built models that adapt automatically when values change. This approach makes the design process far more efficient, since a single sketch can generate many variations while staying fabrication-ready for the laser cutter.
Fusion design for square and circular plates
Fusion workspace showing the square/circle plate set with repeated slot features. Sketch-driven parts ensure consistent fits.

Fabrication & Assembly

The parts were cut from corrugated cardboard using the ULS CO₂ laser. The slots were dimensioned in CAD to account for laser kerf so press-fits land snug without post-processing.

Cubist dog perspective view
Cubist dog perspective view. The orthogonal slot orientations resist twist; the assembled dog stands without glue or fasteners.
Cubist dog side view
Side view showing the structural stability of the press-fit joints.
Top view of assembly
Top view highlighting the spine connection and joint details.

02 · Vinyl Cutting: Delhi Skyline

For the second exercise, I prepared a clean Delhi skyline silhouette. After verifying the outline as a single continuous path, I exported the vector, cut it on the vinyl cutter, and mounted the graphic on a cardboard panel for contrast.

Workflow

  • Vector Design: Traced and cleaned source sketch in Fusion as a single closed profile.
  • Path Integrity: Ensured closed contours and removed self-intersections so the cutter never lifts unexpectedly.
  • Weeding: Simplified tiny voids and set adequate stroke separation to make weeding fast and clean.
  • Mounting: Transfer tape applied in one pass for a bubble-free finish on cardboard backing.
Fusion sketch of Delhi skyline
Source sketch traced and cleaned in Fusion for reliable cutting.

Conclusion

This week provided a solid foundation in computer-controlled cutting. The parametric design approach for the laser cutter proved invaluable for creating a flexible construction kit, while the vinyl cutting exercise highlighted the importance of clean vector paths for graphic fabrication.

Key Takeaway: "Clean edge" adjustments in CAD—adding tiny finishing cuts to slot ends—significantly improve the assembly experience for press-fit parts, preventing material damage and ensuring a smooth fit.