Laser Cut Acrylic Bending Jig

Quick approach to controlling acrylic forming

laser cut acrylic bending jig

Laser cut acrylic has so much going for it, which is why this material’s variants are among the most popular of all the options in the Ponoko Materials Catalog. Designs for laser cut acrylic tend to follow a familiar pattern; boxy shapes, notched and stepped joins and slotted connections. But what happens when your form doesn’t fit this mold?

Ceramicist Chris Donnelly used laser cutting to build himself a basic bending jig that would enable the secondary manipulation of acrylic for his students at the Edinburgh Academy. Consisting of two laser cut side panels that are bolted onto a horizontal platform, the device allows for precise control across 180 degrees of movement thanks to a vertical plane that can pivot and lock into position.

Exactly what the students are making with this jig is yet to be revealed, but it’s great to see how some quick thinking and a clever laser cut design can upgrade the capabilities of their school workshop.

For those inspired to make a laser cut bending jig of their own, the Chris has shared the files on Thingiverse.

 

How To Make a Brushless Motor for Education

Exploring electromagnetism with DIY laser cut motor

laser cut brushless motor

Teaching kids about how motors work can be a lot of fun, particularly when they get to build and experiment on the motors themselves. So when engineer Matt Venn spotted a neat little 3D printed motor, he decided to make his own variation – this time using laser cut components and an Arduino to run the show.

The learning experience

Once all the kinks were worked out, the Arduino was replaced by a few cheap electronic components. This way, students have the opportunity to build the entire setup from scratch, mounting the electronics on a breadboard as they work out exactly what each component does.

The adjustable laser cut rotor has slots to hold different numbers and configurations of magnets, and this can be further extended by cutting custom rotors to suit alternate magnet arrangements.

This is a great project that encourages a hands-on approach to exploring electromagnetism by building a simple DC brushless motor. Consideration has been made to come up with a laser cut solution that can be assembled and studied within the time constraints of a science class workshop.

Matt has provided all of the files and extra info you need to get the motor up and running on GitHub, where you will also find a brief video walkthrough that highlights how the motor and supporting circuitry work.

Matt Venn via Hackaday

Ideas for Creative Agencies & Brands – #38

Hand stitched laser cut action camera case

laser cut action camera case

In almost every sport and active lifestyle pursuit, you will find people strapping on action cameras to document their exploits. These cameras have transformed the way outdoor activities are captured and shared in recent years, and because they provide broadcast quality results at bargain prices, action cameras have become an important piece of kit for professionals and amateurs alike.

While the action cameras themselves tend to be diminutive and relatively discreet, there may still be times when the camera is handy to have around without the need for underwater housings or fancy mounting systems. So what options are out there for the more relaxed uses of an action camera?

Laser Cut face lift

Pictured above is a laser cut leather case for a popular budget-level action camera. Designed by Seoul-based Architect Eduardo Chamorro, the laser cut protective sleeve will give minor protection from bumps and scratches and it is also valuable as a lighthearted way of creating a different visual presence for the camera.

How can this help your brand?

If you deal with people engaging in an active lifestyle, there is a good chance that many of them already own (and use) an action camera. There is also a high probability that these users care about how they look, and this will extend to their techno gear – it kind of goes along with the territory. Creating a custom accessory for an action camera will provide a strong visual reference that differentiates from the classic robust utility of most action camera designs.

Instead of a cheap silicon overmold, a laser cut action camera case can provide a visually appealing option for when the camera is not actually in action. The example from Eduardo is held together with crafty looking hand-stitched yarn, which adds a homely aesthetic that helps to soften the hardcore ‘action camera’ styling of the product. There is also scope to use laser etching to add text, logos, brand messaging or other customisations to the leather surface.

For further images and files for Eduardo’s laser cut camera case see the project page on Thingiverse.

What other active gear can be customised for your clients using the Ponoko Personal Factory? Let us know in the comments below. For more ideas for Agencies and Brands, see the other posts in the series.

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Laser Cut Memory Card Holder

Hey – Stop Losing Your Memory Cards

memory card holder

There is a good chance that Barcelona-based Industrial Designer Róger Zambrano isn’t the only one out there concerned about losing his memory. While (for now, at least) his mind may be very much intact, it’s keeping track of those diminutive memory cards that prompted him to come up with this neat laser cut storage solution.

The drawer-like system contains slots for three SD cards, providing physical protection in a compact package. In fact, the design (which he has made available to download for free on Thingiverse) allows for two of the neat SD card holders to be cut from a single A4 sized sheet of 2mm cardboard. There is also plenty of space for some custom laser etching on the surface.

memory card holder 3

In a bold reminder to himself, Róger has called his card holder HSLYMC which is a truncated version of the phrase: Hey – Stop Losing Your Memory Cards.

via Róger Zambrano

 

Ideas for Creative Agencies & Brands – #37

Laser Etched QR Codes

laser QR 1

Our devices are talking to each other every day, and with all this chatter going on, making new connections or transferring data should be an effortless process. Technologies such as NFC (Near Field Communication) and QR (Quick Response) Codes help to make these digital interactions smooth and simple. Continue reading to discover how you can use laser cutting to integrate these technologies into your products.

How does NFC and QR work?

For NFC to work, information is encoded onto an embedded chip. When two devices containing NFC chips come into contact (usually in the form of a bump or light tap) a process is engaged – payment could be transferred, data and audio connections established or other tasks involving interaction between the two devices.

QR codes operate much like a barcode; they contain a set of reference information that can be scanned using the camera on a smartphone. This prompts the device to access information such as a website address, play a video, or (as in the example above) display login credentials.

Why is this useful for your brand?

The ability to seamlessly connect can give your customers immediate access to a deeper level of information. This means you can add collateral such as image galleries, video clips and other detailed supporting content without consuming valuable real estate on your product. There is much scope to have fun with QR Codes as well as to use them for sensible, straightforward communication.

In the example shown here, Instructables user BWRussell needed a way to share the login details for his wireless network. Tired of spelling out the passphrase to relatives and visitors, he constructed his own dongle that houses an NFC chip and a laser etched QR Code. All visitors need to do is tap or scan the code with their mobile device, and they will be granted access to the network.

It is worth noting that when it comes to the actual physical QR code, a similar functional outcome can be achieved with a desktop printer… however, a laser etched QR code has a greater sense of quality and purpose.

Laser QR 2

See more of this DIY approach to NFC and QR from Instructables user BWRussell.

Can your laser cutting make connecting easy using the Ponoko Personal Factory? Let us know in the comments below. For more ideas for Agencies and Brands, see the other posts in the series.

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How To Make a Laser Cut Dremel Chop Saw

Industrialize your mini DIY production line

dremel chop saw 1

Repetitive cutting for projects that require precision parts can be a time-consuming process. The need for consistency and accuracy in making several hundred cuts from small diameter pipes prompted sculptor HTMF Metal Pizza to seriously upgrade his DIY production line.

Why not use a pipe cutter?

The usual way to cut sections from the hobby pipe is to use a pipe cutter, however this tool leaves a small deformation around the inner diameter. Normally this wouldn’t be an issue, but as HTMF’s process requires smooth edges on both inner and outer surfaces, the sections from the pipe cutter are unsuitable for his needs.

Solution: the Dremel abrasive disc

An abrasive disc spinning at high speed will cut with the precision that HTMF is looking for. When controlled in smooth linear movements, the cuts will be quick and clean… so armed with this knowledge he set out to optimise the cutting process to achieve greater speed without sacrificing any accuracy.

“While I tried cutting the tubing free hand, I found I needed a third hand and there was a huge variation in size which required a great deal of re-finishing.”

Introducing the laser cut Chop Saw

The solution was to build a miniaturised ‘chop saw’ mount for his Dremel cutting tool. As well as holding the Dremel and working material securely, the chop saw houses two drawers; one to store Dremel parts and another to catch the pipe sections as they are cut. He also added a scale on the cutting table that aids in achieving consistent lengths with each cut.

dremel chop saw 2

See the full tutorial on how to build a laser cut Chop Saw mount for the Dremel multi-tool on Instructables. You’ll find all the files you need for laser cutting including an adapter for switching between the Dremel hand tool itself and the flexible shaft attachment, depending on which version you are using. The thoroughly detailed assembly instructions are also peppered with tips (and supporting pics) on how to best manage the trickier steps will see you up and cutting in no time.

…and if you’re wondering what’s up with this Instructables creator’s screen name, HTMF stands for Having Too Much Fun! 

 

Animated Laser Cut Fox

Playfully pouncing from frame to frame

laser cut fox animation

The inner musings of talented artist Sarah Capon have been brought to life thanks to an animated collaboration with Industrial Designer Benjamin Donnelly.

The process started off with a neat series of drawings that make up each frame of the animation, capturing the motion and physical suspense as the fox steadies itself before pouncing playfully. Sarah’s sketches were then converted and sent to a laser cutter to be etched and cut from plywood, along with a clever support bracket designed to hold the laser cut fox frames in place during filming.

laser-cut-fox-animation-frame

Watch the full animation in the video below, along with behind-the-scenes footage that gives a good taste of the process that enabled this playful laser cut animated outcome.

Sarah Capon via YouTube

Laser Cut Open Source Apple Watch Band

Introducing a different approach to achieving affordable designer customisations

OpenBand-on-AppleWatch

For those fans of the Apple Watch who like to put their own individual spin on the tech that they wear, the Open Band concept proposes to further accessorise this iconic designer accessory.

Existing currently as an in-progress exploration from Brooklyn-based rapid prototyping specialists Breakfast, the Open Band project has taken cues from the official range of Apple watch bands, and given them a laser cut makeover. The goal was to allow makers and designers with access to a laser cutter (or a service like Ponoko!) to design custom watch bands that are both stylish and affordable using familiar laser cutting materials.

OpenBand-White-on-Watch

OpenBand-Prototypes

“…we attempted to create an open source design file that would allow people to create a unique, low-cost Apple Watch band which could be laser cut from a number of unique materials, such as: wood, acrylic, acetal, etc.”

The time may be right for this project to see the light of day, but interested Apple Watch wearers will have to be patient… with no definition from Breakfast as to when, if ever, the open source design files will be released. Even still, Open Band is a thought provoking example of how laser cutting can further democratize fancy fashions in the world of high-end design.

source: Breakfast

Ideas for Creative Agencies & Brands – #36

Laser Cut Cross Stitching

laser cut cross stitch

The crafty, handmade look of cross stitch embroidery has something wonderfully warm and fuzzy about it. While the regular grid of holes speaks of an industrial precision, the contrast of woven yarn introduces a human element that is organic and inviting.

Laser Cut Cross Stitch Inspiration

The pendant above was made by Rebecca from Hugs are Fun as a gift for her dad. Over time, Rebecca has refined her techniques to become a bit of an expert at making all kinds of laser cut cross stitched whimsies. It’s well worth browsing through her website for inspiration, patterns, project ideas and even items to purchase.

How to use Laser Cutting for cross stitching

Cross stitching describes an embroidery technique of tracing out patterns using yarn or other coiled materials. In these particular examples, the yarn is threaded through a defined pattern of laser cut holes to generate the raster-like effect. With a little creative thought and planning, you can come up with many interesting variants based on this core idea.

The material of choice can be any of our usual laser cutting favorites. Bamboo ply, acrylic, metals or even leather and felt will all respond well as substrates for the cross stitch technique.

For versatile cross stitched patterns, a grid of laser cut holes will allow for quirky pixellated artwork or logos. It can also be effective to cut only the holes you need to define the form; leaving the substrate surface bare either to have presence in its own right or as an optional space for further laser etched details.

Can you give your brand a cross stitched crafty twist with the Ponoko Personal Factory? Let us know in the comments below. For more ideas for Agencies and Brands, see the other posts in the series.

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How To Make an All-Wooden Laser Cut Padlock

Keeping your treasures safe 

laser-cut-lock

Knowing that your valuables are securely locked away gives peace of mind, whether you are storing the jewellery inherited from your grandma or the secret plans to your Next Big Thing. Perhaps you just need to keep someone out of your private space, or to seal off the cupboard under the stairs from monsters that lurk in the dark.

Whatever the reason is, a lock and key can be handy indeed. So instead of heading down to your local hardware store to buy one, how about building a fully functional laser cut lock of your own?

This simple and clever design from Thingiverse user PArtzzles will prevent prying fingers from finding their way into your box of treasures. The design for the laser cut lock was worked out on Inkscape, and files are available to download so that you can make a version of your own at your favorite laser cutting service. Some makers might like to adapt the lock to further boost its security credibility to a level that will stop thieves in their tracks. Well… that’s the idea, at least!

via Thingiverse