؜In higher-fidelity cardboard models, the pieces might be laser cut, and other materials might be introduced to work with the cardboard pieces (including motors/ electronics).

Prototype One

Prototype Two

Prototype Three

Iteration

Digi-Fab

A Collection of Tools

Digital fabrication refers to the use of computer-controlled tools and processes to create physical objects from digital designs. It's an umbrella term that encompasses various technologies, including 3D printing, laser cutting, CNC machining, and more

3D Printer

Laser Cutter

Vinyl Cutter / Plotter

CNC Milling Machine

Waterjet Cutter

Laser Cutting

What Is It?

؜Laser cutting is a manufacturing process that uses a high-powered laser beam to cut, engrave, or etch materials into specific shapes or designs. This process is controlled by a computer and is often used on materials like wood, metal, plastic, and fabric. The laser precisely follows a digital design, allowing for intricate and accurate cuts and engravings.

WHAT CAN A LASER CUTTER DO?

Cut

The laser cutter directs the beam of a laser to burn through the material in whatever pattern you design

Etch

The laser cutter can decrease the laser power to burn the surface of the material, but not cut through

Laser Cut

Laser Engraving

MATERIALS

Cardboard  3/16” 

Ensure it is laying flat

Cardstock Paper  60lb or thicker 

Be careful to watch while cutting

Plywood & Hardwood  1/8" or thinner  

Baltic Birch plywood is best

Acrylic  1/8" or thinner  

Don’t cut any other types of plastics

Leather  1/8" or thinner  

Ensure it is laying flat

Glass and Metal  Etching only

Cannot cut through

3D Printing

Laser Cutting

Can create more complex parts

Low cost & less waste

Huge support community

Generally slower than laser cutting

Post processing may be required

More experience needed to 3D model parts

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Extremely fast & precise

Can quickly etch details

Material range

Requires active ventilation

Higher cost

Less community support

VS

Mock up Prototype

Final Prototype

Sketch

Process to Digital Fabrication

Mindfulness Eating Kit

Low-Fidelity

High-Fidelity

Realistic Motion Wings

Green Planet

Software

To laser-cut your design, export it as an SVG (vector) file and send that to the printer or laser-cutting service. There are many programs and workflows you can use to create SVGs.

1. XTool (Free, very easy)
2. Inkscape (free, intermediate)
3. Adobe Illustrator (, intermediate)
4. Fusion 360 (Free for educators , intermediate)
5. AutoCAD (License needed , intermediate)
6. Rhino ( License needed , Advanced )

File types [SVG / DXF]

Designing for Laser Cutting

Designing for Laser Cutting

When designing, you must think like the machine.

Design rules

1. Lines = cuts
2. Closed shapes cut out
3. Stroke color or thickness often defines cut vs score

Important

1. No overlapping lines (or danger of burning)
2. Use vectors, not images
3. Keep designs flat (2D)

Black: Cut & Green: Scoring

Laser Cutting Applications

Press Fit Designs

Simple Boxes

Laser cutting is great for building without glue.

Furniture/Architectural Structures

Laser Cutting Applications

Press Fit Designs

Waffle

NuVu Examples

Waffle Cyclinder

Layered Cyclinder

Laser Cutting Applications

Mechanisms

Laser-cut parts can create moving systems.

Automata

Series of mechanism

Iris Shutter

Laser Cutting Applications

NuVu Examples

Cardboard Mechanisms

Laser Cutting Applications

NuVu Examples

Eccentric Cam

Scissor Lift

Wooden Mechanisms

Servo Arm

Planetary Gears

Barrel Cam

Parallel Linkage

Linear Ratchet

Piston

Laser Cutting Applications

NuVu Examples

Wooden/Cardboard Mechanisms

Cardboard

Wood

Cardboard

Laser Cutting Applications

Kerfing

Solid materials don’t like to bend.

Kerfing creates tiny gaps that allow movement.

More cuts → more flexibility

Fewer cuts → stiffer structure

The word “kerf” = the width of material removed by the laser

Always do a test strip first:

1. Same material
2. Same thickness
3. Different spacing

Laser Cutting Applications

Kerfing

NuVu Examples

Laser Cutting Applications

Auxetics

Auxetic structures behave in a surprising way: They expand when stretched. Why they’re interesting? Flexible but strong

Used in fashion, architecture, biomedical design, packaging

It's created by repeating geometric cut patterns

Laser Cutting Applications

Auxetics

If the laser can remove a piece, it’s probably wrong for auxetics.

Good auxetics:

1. No loose parts
2. No falling pieces
3. Everything stays connected

Laser Cutting Applications

Auxetics

Laser cutters work best with flat, sheet materials that respond well to heat.

The most commonly used materials are:

1. Cardboard
2. Wood (plywood & MDF)
3. Acrylic Fabric
4. Leather

Laser Cutting

Student Work

The "Klutz" Robot

Lottery Pig

Rivalship

Octo

GEARS

SCISSOR

SLIDER

RAMP

PULLEY

TENTACLE

• Cardboard
• Straw
• String

How to make it

1

4

2

3

Cut the cardboard into a long rectangle

Bend the cardboard into segments (about 1-inch long)

Cut the straw into half-inch pieces and hot glue them into the center of each segment

Thread the string through the straw pieces and secure it by tying or glueing to the top of the cardboard

SPINNER

CLAW

How to make it

1

2

Fold the triangular column on the perforations. Glue the triangle caps onto each end.

Glue two hook pieces together to make a wider/ stronger hook. Repeat three times.

How to make it

3

4

Glue the smaller round piece onto a larger piece. Slide a hook onto the small wood dowel. Glue into the notch. Glue on the larger cap.

Slide each of the three longer cardboard strips through the holes in the claws.

How to make it

5

6

Put the wood dowel through the holes in the triangular column, then the claw piece. Glue the circular cap onto the top of the dowel and claw piece.

Glue the center of the smaller cardboard strip onto the side of the triangle. Sandwich the ends of the long cardboard strip inside this piece. Repeat on each side.

؜Auxetic designs are:

Mostly lines + Not filled shapes + Repeating patterns

Why?

Lines act like: Hinges, springs and joints

؜Auxetic behavior comes from how we cut the material, not what it’s made of.

The Secret Is the Shape

The same pattern can work in:

1. Cardboard
2. Wood
3. Rubber sheets

؜Auxetic designs are:

Mostly lines + Not filled shapes + Repeating patterns

Why?

Lines act like: Hinges, springs and joints

By laser processing bending cut geometries or ‘kerf cut’, sheet materials that are rigid such as acrylic and wood can be bent. Most types of wood will adapt extremely well to cutting techniques with bending applications.

We recommend:

1. Plywood & MDF

Techniques for acrylic cutting.

Cutting techniques associated with acrylic are best for rigid bends, e.g. boxes or cases where the bending radius is very rarely changed. With a continuous load of the cutting pattern, e.g. with a book, the webs can easily break.

When processing acrylic, the following points must be observed:

1. A 2” lens (at minimum) should be used for laser cutting with bends. Since acrylic will melt from the heat of the laser beam, if the focal length of the lens is too small, it may result in the cut areas sticking back together.
2. We suggest using a cutting distance of around 1-1.5 mm. If melting occurs even with the appropriate lens being used, try increasing the distance between the individual cut lines. However, if the distance used is too large, bend flexibility will decrease.

Kerf 1: Straight cut lines

Cutting small interconnected waves will give the material a large bending radius and flexible appearance. This technique is best suited for materials that are up to 3 mm thick.

Kerf 2: Small waves

With large honeycombs, the curves are cut out of the sheet and tapered at each end. Because of the large honeycomb, wooden boards can be used with flexibility up to about 5 mm thick. This pattern is most commonly used in model making.

The honeycombs can be easily taken apart as well as put together, and can also be combined with connections, such as with bracelets for example.

Kerf 3: Large honeycombs

Similar to pattern 1, this laser cut pattern consists entirely of cut lines, but offers different bending properties as it is much more flexible.

Kerf 4: Wavy cut line

The uniquely formed pattern of this bending cut offers flexibility in all directions, which makes a variety of creative applications possible, such as in bag design for example.

Kerf 5: Honeycombed cut line

These cuts are versatile and work well with several different types of materials. The shape given to the individual cut lines allow for flexibility and stability.

Kerf 6 and 7: Wide and narrow waves

Due to its design, this cutting pattern is most commonly used as a graphic element and can be bent in all directions.

The triangular shape of this cutting technique is well suited for materials up to around 3 mm of thickness, and becomes inflexible and rigid after 5 mm or more.

Kerf 8: Triangular shape