Week 02: Computer-Controlled Cutting

Assignments

🔧 Parametric Construction Kit

Design and fabricate a modular construction kit using parametric design principles and laser cutting techniques.

Status: Completed - Cubist dog assembly

📄 Vinyl Cutting Project

Create a vinyl sticker or decal using vector graphics and vinyl cutting techniques.

Status: Completed - Delhi skyline panel

📚 Documentation

Document the complete design and fabrication process with detailed explanations and images.

Status: Completed - This page

🛡️ Safety Training

Complete laser cutter and vinyl cutter training and safety certification.

Status: Completed - Machine certified

Tools & Materials

🖥️ CAD Software

Autodesk Fusion 360 - Used for parametric design, sketch-driven modeling, and preparing vector files for cutting.

Parametric modeling with constraints: For this week’s assignment I experimented with parametric modeling and constraints in Autodesk Fusion to create pieces that could be adjusted and reused in different designs. 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.

DXF export for laser cutting

SVG export for vinyl cutting

⚡ Laser Cutter

Universal Laser Systems (ULS) CO₂ Laser - High-precision cutting for cardboard and other materials.

Kerf compensation in design: .

Precise parametric joints

Clean edge finishing:

📄 Vinyl Cutter

Roland Vinyl Plotter - Precision cutting for adhesive vinyl graphics and stencils.

Vector path optimization

Weeding and transfer techniques

Clean application methods

🧱 Materials

Corrugated Cardboard & Adhesive Vinyl - Primary materials for both cutting assignments.

Cardboard: Structural assembly

Vinyl: Graphic applications

Transfer tape for mounting

01 · Parametric Joinery → Cubist Dog

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. In Fusion, this can be done automatically by extending the toolpath or adding a straight-line cutout at the edge of each slot. This “clean edge” adjustment doesn’t change the overall joint fit but prevents corners from binding and tearing. The result is a more forgiving slot where the force of assembly is distributed evenly, instead of concentrated at sharp edges. By integrating this feature directly into the CAD model, the laser produces slots that are both precise and easy to use, eliminating the need for manual filing or rework after cutting.
ßI 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.

Sketch‑driven parts. Square and circular plates share a single slot profile—edit once, propagate everywhere for consistent fits.

Kerf‑aware slots. Slots were dimensioned in CAD to account for laser kerf so press‑fits land snug without post‑processing. 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. In Fusion, this can be done automatically by extending the toolpath or adding a straight-line cutout at the edge of each slot. This “clean edge” adjustment doesn’t change the overall joint fit but prevents corners from binding and tearing. The result is a more forgiving slot where the force of assembly is distributed evenly, instead of concentrated at sharp edges. By integrating this feature directly into the CAD model, the laser produces slots that are both precise and easy to use, eliminating the need for manual filing or rework after cutting.

Stable compound object. Orthogonal slot orientations resist twist; the assembled dog stands without glue or fasteners.

Fusion design for square and circular plates with parametric slots

Fusion workspace showing the square/circle plate set with repeated slot features.

Top view of assembly highlighting the spine connection

Laser‑cut corrugated cardboard; no glue. The slot system locks planes in place for a tight fit.

Fusion sketch of Delhi skyline silhouette

Source sketch traced and cleaned in Fusion as a single closed profile for reliable cutting.

02 · Delhi Skyline — Vinyl Cut

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.

Single‑path integrity. Ensured closed contours and removed self‑intersections so the cutter never lifts unexpectedly.

Weed‑friendly design. Simplified tiny voids and set adequate stroke separation to make weeding fast and clean.

Clean mount. Transfer tape applied in one pass for a bubble‑free finish on cardboard backing.

Shown below in the gallery is the skyline panel next to the cubist dog prototype.