Laser cutting

 Laser Cutting documentation Blog Entry

Hi, welcome to my first blog for this module👋! In this blog, I will be describing the following: 

1. The 4 important hazards associated to the operation of laser cutting machine and their respective safety control measures (administrative/ engineering control).

2. The materials that can be cut and can't be cut using a laser cutting machine.

3. The steps including pictures on the operation of UNIVERSAL laser cutter, that consist of: 

a) Starting the Compressor, turning on the laser cutter machine and fume extractor  

b) Importing a DXF. file to corel draw and modify the lines/fill for cutting and engraving

 c) Sending the coreldraw drawing to laser cutter software and setting the laser cutter power, speed, PPI in the software. 

d) Starting the job on the laser cutter machine

 e) DOs and DONTs when there’s flame/fire on the material being cut. 

4. My Learning reflection on the laser cutter activities 


So before starting on laser cutting, it is important to know the different hazards that exist while operating the laser cutting machine. 

1. These are the 4 important hazards and the respective safety control measures on the operation of laser cutting machines:

Hazards

Safety control measures

Pictures to support the explanation

  1. Materials might catch fire during laser cutting

  • Always remove any paper sticking onto the surface of the material 

  • If the fire occurs is negligible, just put it out by blowing it immediately

  • If the fire is unable to be put off by blowing it, put the material on the floor and step it to extinguish the fire.

  • If the fire is getting too big and uncontrollable, find a fire extinguisher to extinguish the fire immediately and shout for help.

  1. Fumes and gases generated from laser cutting

  • Make sure to switch on the fume extractor when using the laser cutter.

  1. Staring at the laser beam 

  • Do not to stare at it but instead, take glances would be enough to monitor the cutting process.  

  1. Residue and debris that is left in the laser cutter might cause fire hazard

  • Before the start of the laser cutting, make sure that no residue and debris is present in the laser cutter

  • After the laser cutting, do housekeeping by removing the leftover material and residue that is left in the laser cutter.


2.   Below are the materials that can be cut/engraved using laser cutting machine in FabLab.

Material

Photo of material

  1. Plywood

  1. Natural wood (May cause small fires)

  1. Cardboard (Burnt marks and fire may occur)

  1. Acrylic

  1. Art card (Burnt marks and fire may occur)


Below are the materials that can’t be cut/engraved using laser cutting machine in Fablab.


Material

Photo of material

  1. PVC

  1. Foam 

  1. Metals

 

3.  Below are the steps for the operation of the UNIVERSAL laser cutter machine in FabLab:


a. Starting the compressor, turning on the laser cutting machine and fume extractor.

Steps and description

Photos to support the description

1. Switch on the power for the laser cutter, air assist, and extractor


b. Importing a .DXF file to coreldraw and modify the lines/fill for cutting and engraving.


Steps and description

Photos to support the description

  1. Select ‘file’ → ‘import” → select your dxf. file

2. To modify the lines, click on ‘Tools’ on the bottom right hand side

 

Following are the steps for vector cutting, engraving, and vector-engraving, depending on the user's preference

  • Vector cut → Pen outline colour: RGB RED

Line width: Hairline

  • Engrave → Fill colour: RGB GREEN

Line width: none

  • Vector-engrave → Pen outline colour: RGB GREEN

Line width: Hairline


*RED (R:255, G:0, B:0)

*GREEN (R:0,G:255, B:0)









c. Sending the coreldraw drawing to laser cutter software and setting the laser cutter power, speed, PPI in the software.


Steps and description

Photos to support the description

  1. To send to print, select ‘file’ → ‘print’ 



  1. Click on the cogwheel icon beside the printer selection



  1. Select ‘load’ to select material 



  1. Select the respective material type and thickness of the material → click ‘open’



  1. Some important things to take note: 


  • The red and green colour should be on rast/vect mode (*cannot be in ‘skip’ mode)


  • Power describes the output of the laser and it usually does not go over 50%


  • Speed describes the movement of the laser head. It is usually set to a low speed


  • Pulse per inch (PPI) is a way to control how many times the laser pulses over a given distance during the cutting process. It is usually set to a high frequency.


  • Z-axis is Usually set as the material height for optimal focus point.




d. Starting the job on the laser cutter machine.

Steps and description

Photos to support the description

  1. Open up the Univeral control panel (UCP) icon shown on the task bar



  1. To start, activate the laser cutter by clicking onto the red button located at the side of the play button. (The play button will turn from grey to green)



  1. Ensure that all the paper that is sticking on the material that is facing upwards is to be removed (TOP only). The bottom can don’t remove so that it can protect the plastic  


  1. Place the material on the top left hand corner (ZONE 1)



  1. to relocate it, just type in the value x=0.5mm y=0.5mm in the ‘relocate view’ (it is not recommended to relocate them to (0,0) because the material sometimes might not be straight at the corners.

  • If you find that some of the corners might have problem, just click onto the ‘focus view’ (also known as laser pointer) to locate where you when you object to start printing at →click on the ‘relocate view’ →select the top left white colour point that is around your object.→click ‘to pointer’ (this will allow white colour point that you’ve selected to go to the last location where the laser pointer went) 



  1. When you are happy with the settings, gently close the lid


  1. Press the green play button on the screen or press the physical green button on the machine







Shutdown

  1. DO NOT LIFT the lid immediately, let the extractor remove the toxic smell & particles first. For your own safety, wait for around 1 Minute before lifting up the lid!


  1. After the extraction of the smell, gently lift up the lid and check if the material is thoroughly cut through


  1. Tap on the material to see if it is free from the main material. (if never cut through means the lenses is dirty. Inform the teacher in charge that its dirty)



  1. Deactivate the machine by clicking on the red button again


  1. Remove any leftover material or debris from the laser cutter 



  1. Switch off the power supply for laser cutter and fume exhaust

  • You need not shut down the PC




e. DOs and DONTs when there’s flame/fire on the material being cut.

DOs and DON’Ts

Photos to support the description

DOs


Any flame must die out within 1-2s. If the flame persist, lift up the lid of the laser cutter to stop the operation.


  • If the fire occurs is a small one, just put it out by blowing it immediately

  • If the fire is unable to be put off by blowing it, put the material on the floor and step it to extinguish the fire.

  • If the fire is getting too big and uncontrollable, find a nearest fire extinguisher to extinguish the fire immediately and shout for help.


DON’TS 


Do not run away without informing  anyone about the fire 



4.   Below is my Learning Reflection on the laser cutter activities.


So far, i find that laser cutting is very interesting and i enjoyed it a lot other than writing out the SOP. However, it is very useful to write out our own SOP as compared to just reading off the SOP that was provided for us because this actually helps me to better understand what are the correct steps to do and what not to do during laser cutting. 


In the first week, we went through tutorial lessons on laser cutting. Honestly speaking, i was very blur on how does laser cutter work when Dr Noel first explained in class. But after going through the learning package and writing out the SOP myself, everything became clearer. I always thought that all laser cutters can cut metals, guess what? I’m wrong! We are not allowed to cut metals in the fablab as it is relatively dangerous to do so.😓 I only knew this when i go through the learning package. 


While writing the SOP, i went through the video a lot just to make sure i don't missed out anything. However when it comes to the real competency test, it was actually very scary although the test was quite simple after thinking back.😖 I remembered that i made a few mistakes but i managed to correct it back myself without any reminder.


Although i passed the competency test, i feel like there are still a lot of things that i need to improve on. For example, navigating the coreldraw and making designs with it. 


Overall the experience was good and the process for the cutting or engraving was very fast and i can get my product in less than a minute. 


Here is the product that i’ve made during the competency test👻:





































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