Beginners Laser Cutting Cost Saving Guide: Part 3

Keep your laser cutting costs down with the Ponoko Product Recipe

Product Recipe #1 – Part 3

Jill is a graphic designer from Oakland, CA. While riding her bike to work, she was inspired to create a set of custom-made bike gear-themed coasters to sell at local bike shops and in her Etsy Store.

Here Jill takes you step-by-step through the process she used to turn her idea into a profitable product with Ponoko. Making her coasters at the lowest price possible means she pockets a healthy margin selling to stores and direct to customers.

You can apply these steps to your own project, or you can download all the files here.

Laser Cutting Cost Saving Guide Part 3: Prototype It

My goal was to find a happy compromise between design aesthetics (look/feel) and efficient engineering (cost).

Zero Cost Prototyping!

Before I paid to make anything, I used my Personal Factory to price lots of design iterations instantly. I learned a whole lot and it didn’t cost me a bean …

Summary:

Target Production Cost = $1.88 per coaster (75% off retail).
First Quote – #1 = $5.40 per coaster (28% off retail).
Final Quote – #9 = $1.64 per coaster (78% off retail) !!

Here’s what I did to reduce my production cost, without actually making anything:   (more…)

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Laser Cutting Royal Lions

Laser cut lanterns, signs, skulls, and a map!

Above is a laser cut paper street lamp. This work, cleverly transforming flat media like Ponoko’s cardstock into 3 dimensions, is from Paper Faber and looks just as good flat as it does “poped” up. See another look at this street lamp at the end of this post!

After the jump signs, skulls, and a map… (more…)

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Ideas for Creative Agencies & Brands – #9

Laser Cut DVD Sleeves

Distributing large files on optical media continues to provide significant bang for your buck… even in these times of ever-cheaper flash storage. So if you’re still using discs as a way to distribute your digital wares, why not show off some creative flair with the packaging that goes along with your promotional CD, DVD or Blu-Ray?

The particularly refined laser cut case pictured above comes from designer Jazz Tigen and it is a great example of the impact that can be achieved when you break away from the standard DVD sleeve.

Here are a few more approaches that others have taken in creating unique CD and DVD sleeves through clever use of laser cutting.

Sarah Holbrook

Stine Strand

Neslihan Ulus

What examples have you seen of businesses or musicians using laser cut packaging designs for optical media? Let us know in the comments below.

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Laser Cutting In Her Eyes

Laser cut art, Daleks, dogs, hops, and clock!

Above is an artwork titled “Rusty Girl” from perishable Rush. It is made from paper found on the streets of Amsterdam, comic book, magazine pages, and torn screen prints which form a ski mask around laser etched, halftone eyes and a mouth. Halftone is a printing technique that using variant sized dots to create light and shade out of photographs and is well suited to laser raster engraving on Ponoko’s own cardstock or mix it up with acrylic.

After the jump, Daleks, dogs, hops, and clock… (more…)

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Beginners Laser Cutting Cost Saving Guide: Part 2

Keep your laser cutting costs down with the Ponoko Product Recipe

Product Recipe #1 – Part 2

Jill is a graphic designer from Oakland, CA. While riding her bike to work, she was inspired to create a set of custom-made bike gear-themed coasters to sell at local bike shops and in her Etsy Store.

Here Jill takes you step-by-step through the process she used to turn her idea into a profitable product with Ponoko. Making her coasters at the lowest price possible means she pockets a healthy margin selling to stores and direct to customers.

You can apply these steps to your own project, or you can download all the files here.

Laser Cutting Cost Saving Guide Part 2: Design It

Now that I had an idea of where I wanted to go, it was time to prepare my first design for laser cutting. Here are my top tips.

Download a Laser Design Template

Open a Personal Factory laser design template in Adobe Illustrator. Using the template makes it so much easier to get a good result.

Use Existing Images

I did an image search to find a few gears with crisp images on a clean white background to make outlining easier:

Next – I imported the images into Adobe Illustrator, and converted the gears into black outlines:

Get the Essentials Right – Line Colors & Widths

I needed to use these settings to cut along the lines of the gear drawings:

* Stroke Color – Blue (R0, G0, B255).

* Stroke Width – 0.01mm.

To engrave along the lines of the gear drawings I needed to use these settings:

* Stroke Color – Red (R255, G0, B0).

* Stroke Width – 0.01mm.

To summarise Part 2 of the Laser Cutting Cost Saving Guide; Jill downloaded a design template from Ponoko, selected an image and refined the linework in Illustrator, and then ensured that the line colors and widths were compatible with the laser cutting guidelines provided in the template.

With the design sorted, our next step is to look at making a prototype. Continue reading Part 3 of this Ponoko Product Recipe for handy tips that will keep your laser cutting costs as low as possible.

How do you prepare your designs so that they are ready for laser cutting? Tell us about your process in the comments below.

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Laser Cutting – It’s Like A Unicorn Wearing Roller Skates

A laser cut unicorn, a phone dock, an Astro Boy lamp, and a mother’s day card!

Above is a laser cut and etched wood floss organizer of Rasalie Gale’s iconic unicorn (on roller skates) design – here with the floss making its colorful mane. It was made by 6 By 6 Arts.  It was made using 1/4″ plywood like Ponoko’s own Veneer MDF – Cherry which allows for smooth cut edges and clean Raster Engraving.

After the jump, a phone dock, an Astro Boy lamp, and a mother’s day card…

(more…)

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Laser Cut Letter Stamps

Watch this designer font break free from the digital world

Amongst other things, Tyler Finck designs fonts… and quite beautiful ones at that. Looking for an interesting way to take his digital typography a little further, the font Upstater Regular was selected to be transformed into stamp blocks using a laser cutter.

While we don’t get to see what the stamps will actually be used for, Tyler has posted a neat little clip of the laser cutter in action. The whole character set took 25 minutes to cut and etch, leaving him with a collection of miniature stamps that can now go on to create analogue artworks or literary masterpieces… or perhaps just compose the words for short personal messages; sending sweet nothings in a way that inkjet printers can only dream of.

via Tyler Finck on YouTube

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Beginners Laser Cutting Cost Saving Guide: Part 1

Keep your laser cutting costs down with the Ponoko Product Recipe

Product Recipe #1

Jill is a graphic designer from Oakland, CA. While riding her bike to work, she was inspired to create a set of custom-made bike gear-themed coasters to sell at local bike shops and in her Etsy Store.

Here Jill takes you step-by-step through the process she used to turn her idea into a profitable product with Ponoko. Making her coasters at the lowest price possible means she pockets a healthy margin selling to stores and direct to customers.

You can apply these steps to your own project, or you can download all the files here.

Laser Cutting Cost Saving Guide Part 1: Imagine It

First up, I needed a plan. A clear idea of my product, who it would appeal to and how much I needed to make and sell it for in order to turn a profit.

Your Product User

Take a moment to consider who will be using your product, and why. I had bicycle enthusiasts and their thirsty friends in mind.

Your Product Design

Rough out your design. I mostly tried to get a few ideas I had floating around in my head onto paper.

Your Product Materials

My coasters needed to look good, but also stand up to repeated use. I was thinking materials like black acrylic or natural cork. So I bought a few $2.50 material samples. I kinda liked the cork:

Your Target Price, Cost & Profit

Some basic research showed a set of 4 custom-made coasters retails for between $15 and $50 – with many sitting around $30. Working backwards, I calculated my ideal price points.

Your Design Challenge

Now you have your design challenge. Mine was to design a set of 4 bicycle themed coasters at less than $7.50 for making, materials and shipping from my Personal Factory. That’s a target production cost of $1.88 per coaster (75% less than a retail price of $7.50 each).

To summarise Part 1; Jill has identified her market, roughed out a design, investigated material options and worked out her design challenge based on a realistic retail price point.

In the next instalment for this Ponoko Product Recipe, we take a look at the digital design process for making a laser cut bike gear coaster. Jill talks us through preparing a file that is ready to send to the laser cutter.

Have you used Ponoko material samples to help in the early stages of your own design process? Tell us about it in the comments below.

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How to: Turn a Logo into a Laser Cut Item

Achieving low cost, high quality results quickly and easily

Starting your own line of products can be a challenge, particularly if you’re competing against companies with established backgrounds in manufacturing. By using the Ponoko Personal Factory, you can achieve a refined, professional result with surprising ease.

The following tutorial walks through the process of adding a laser cut logo to a series of products, from the initial napkin scribbles all the way to a final outcome that can stand proud amongst all the other shiny products in the front window of a store.

The project we are looking at is a logo for a custom line of amplifiers. The client requested a finish that would match the mid-century styling of the product casing, keeping things looking modern while retaining a connection to the classic rocker feel of the product line.   (more…)

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Top Ten Ways to Reduce Laser Cutting Costs

Understanding how to get the most out of your Personal Factory

Have you ever wondered how to reduce your laser cutting costs? Whether you are making for profit or just for fun, it always helps to know you are getting the most bang for your buck. Ponoko’s series of Top Ten Ways To Reduce Laser Cutting Costs aims to do just that, by breaking down the key contributors of Making, Materials, and Shipping.

In this overview, we take a look at what was covered in the Top Ten list.

It all begins with understanding how laser pricing works. With Ponoko, thousands of designers are successfully making products at low cost – with many able to achieve comparative savings of up to 90% less than retail.

They’re able to do this because they know how to best use their Personal Factory to design for laser cutting.

The critical things they understand are:

  • Design – EVERY design feature results in more cost. Hence: Start very simple.
  • Materials – EVERY inch is highly valuable area. Hence: Use every inch.
  • Shipping – EVERY order over $100 is free to ship. Hence: Prototype small, finalize bigger.
  • Account – EVERY Prime order cost 32.5% less to make than Free account orders. Hence: Time your upgrade.
  • Volume – EVERY Prime order over $1,000 cost up to 55% less to make than Free account orders. Hence: Time your upgrade.

Avoiding high costs that can give you quite a fright, Ponoko designers understand they need to price test, test, test, test and test again their “brilliant” and “visionary” product designs. A product is rarely brilliant if it never comes to life because the design failed to appreciate the highs and lows of the making process and materials.

Remember that you pay for every minute the laser is cutting, engraving and travelling between cutting and engraving – this means you want a great design that takes as little laser time as possible.

The following design features cost more because they take more time for the laser:

    • Cutting longer lines takes longer than cutting shorter lines.
    • Cutting lots of short lines takes longer than cutting a less detailed design.
    • Cutting two lines on top of one another takes longer than cutting a single line.
    • Cutting circles takes longer than cutting straight lines.
    • Cutting or engraving designs placed far apart takes longer than cutting or engraving designs placed next to each other.
    • Cutting thicker materials takes longer than cutting thinner materials.
    • Cutting harder materials takes longer than cutting softer materials.
    • Engraving lots of lines takes longer than engraving a few lines.
    • Engraving solid fill areas just takes a long time.
    • Shipping larger sheets further cost more than shipping smaller sheets closer.
    • Larger material sheets cost more in total than smaller sheets.
    • Larger material sheets cost less per item on the sheet than smaller sheets.

When these considerations become a part of your workflow it will make a huge difference to how much your laser cutting costs.

In the Ponoko series of  Top Ten Ways to Reduce Laser Cutting Costs, the key considerations of making, materials and shipping have been optimised to give you the best possible outcome. So keep this list handy and follow the advice; ask us questions in the comments below if you get stuck on anything… and we look forward to seeing what you make next!

Ponoko’s Top 10 Ways To Reduce Laser Cutting Costs:

1. Digital Prototyping

2. Paper Prototypes from your home printer

3. Make a cardboard version first

4. Start small

5. Keep Details Simple

6. Avoid Double Lines

7. Group Parts Together

8. Line vs Area Engraving

9. Material Thickness

10. High making costs? Try Ponoko Prime

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