EG-UY 1004 Laser Cutting Guide
Table of Contents
EG-UY 1004 Laser Cutting Guide
When Should You Use Laser Cutting?
How to Prepare Files for Laser Cutting
What is Laser Cutting?
Laser cutting is a manufacturing process that uses a high power laser to engrave or cut materials, with precision. For most students in EG-UY 1004, the most common materials used are birch wood and acrylic sheets.
To begin the process, a file is created and uploaded to the laser cutting machine. Next, a motion control system or computer numerical control (CNC) controls the laser to engrave or cut the pattern into the material inside the machine. This laser beam cuts or burns material to leave behind the pattern that was originally uploaded to the machine.
Vector cutting is the most common form of laser cutting used in this class, as it is used to completely cut through materials and leave behind certain shapes. When vector cutting, the laser follows the outline or profile of the file. This is especially useful when using laser cutting to produce precise 2D parts or small shapes.
When Should You Use Laser Cutting?
When designing your prototype, first consider the purposes of different types of manufacturing methods and what works best for the plan. In general, laser cutting is the best method for larger, precise, flat parts. For sensor housing generally shaped like a box, flat pieces can be laser cut and secured together to create a stronger, less wasteful alternative to 3D printing (Figure 1).
Figure 1: Lasercut Housing Unit, Former EG Student
However, laser cutting is not the best manufacturing method for all purposes. It is limited to flat surfaces, so it is generally ineffective for more complex housing. If you have sensor housing that may not be easily laser-cut, 3D printing should be used instead.
Laser cutting for EG-UY 1004
The process for laser cutting in this class is as follows:
- Prepare a file to laser cut.
- Submit Laser Cutting Request Form.
- If one of your team members does not have the MakerSpace Laser Cutting Training, you should include availability to come to Open Lab and cut your design.
- Wait to receive an approval email with a time to come into the Open Lab.
- If a team member already has the MakerSpace Laser Cutting Training, they can book a time with the makerspace and cut it themselves.
- Pick up materials in the Open Lab and go to the Makerspace with an EG TA.
- The EG TA will cut material and you can collect it.
How to Prepare Files for Laser Cutting
There are many programs that can be used to create files for laser cutting. Here, we introduce common software – CorelDRAW, Adobe Illustrator, and Makercase.
CorelDraw
CorelDraw is a vector graphics editor that can be used to create files for laser cutting. CorelDraw is available for use on the computers by the laser cutters in the MakerSpace.
To start, create a file by clicking on File > New in the top left corner. Once this is clicked, the file creation settings (Figure 2) will pop up. Set your width and height to that of the material you are printing (ex. Birch Wood 12x24 -> width:24 height:12). Make sure that the color mode is set to RGB Color. Once this is done, click OK at the bottom of the menu.
Figure 2: File Creation Settings
In your file, use the toolbar on the left side of the screen (Figure 3) to create your design. There are various tools that can be used to create lines, shapes, or text that can be translated into cuts on the machine. You can adjust these tools using the menu at the top of the screen to change the scale or any details. A vector line is a line that will completely cut through the material, and an engraving will be etched into the material.
Figure 3: Toolbar 4
In order to create a vector line, set the width of the line or object to hairline or 0.001 inches or 0.025 millimeters using the object properties tab on the right. To do this, select the object you would like to turn into a vector line, click the “Object Properties” Menu on the right side of the screen, and change the outline width to hairline (Figure 4) In the object properties tab, you can also fill your object if you would like to add an engraving.
Figure 4: Object Properties
Once your file is ready, you can export it as a Drawing Exchange Format file (DXF) or a Scalable Vector Graphics file (SVG). To do so, go to File > Export and export it as a .dxf or .svg file.
Adobe Illustrator
Adobe Illustrator is a professional vector graphics editor used to create logos, icons, illustrations, and artwork. This can also be used to create vector images that can be used as files for laser cutting.
To create a file to place your design on, you should go to File > New. In the file creation settings, set your width and height to that of the material you are printing (ex. Birch Wood 12’’ x 24’’ -> width:24 height:12). Make sure that the color mode is set to RGB Color (Figure 5). Once this is done, click create in the bottom right corner and you will be left with your file.
Figure 5: File Creation Settings
In your file, use the toolbar on the left side of the screen (Figure 6) to create your design. There are various tools that can be used to create lines, shapes, or text that can be translated into cuts on the machine.
Figure 6: Toolbar
Once you have used the toolbar to create an object, you can edit the properties using the properties tab on the right. For vector lines, the stroke of each line should be set to 0.001 inches or 0.025 millimeters. While different settings allow different thicknesses for vector lines, you should use 0.001 inches or 0.025 millimeters if you want the laser to completely cut through the material (Figure 7). For engravings, you can use the toolbar on the left to create text or designs on the file. As long as the width of these lines is above 0.01 inches or 0.25 millimeters, they will be engraved and not fully cut through the material.
Figure 7: Properties
Once your file is ready, you can export it as a Scalable Vector Graphics file (SVG), a Drawing Exchange Format file (DXF), or an Adobe Illustrator file (AI). To do so, go to File > Save As > export it as a .svg, .dxf, or .ai file.
Makercase
Additionally, you can use resources like makercase.com to create boxes easily. In this website, you can create different types of boxes with custom sizing and shapes. To use this, select the type of box you would like to create and use the customization menu on the left side of the screen (Figure 8). In this menu, you can change the width, depth, height, type of box, and connection method.
Figure 8: Makercase Customization Menu
Once your custom measurements are entered in, press the download button at the bottom of the customization menu. When you do this, a download menu (Figure 9) will appear. In this menu, you can add labels, edit line settings, add cut composition, and change the layout. You should change the cut line width to 0.001 inches or 0.025 millimeters so that the laser will completely cut through the material.
Figure 9: Makercase Download Menu