How To Make a Customized Jigsaw Puzzle

Laser Cut Educational Toys

laser cut puzzle 1

Personalised toys can make a great gift, adding something unique and memorable to show how much you care. It’s one of those things that many people think about doing, but never take the first steps to actually make it happen. Let’s take a look at how easy it can be to put together a personalised laser cut educational toy.

As you can see in this guide on Instructables, it is possible to achieve a highly resolved, professional-looking outcome even for those who are new to laser cutting. The guide, written by Ponoko’s own Dan Emery, walks through a process of creating the cutting pattern for the jigsaw pieces using Inkscape, and then building a custom map section that will become the laser etched details.    (more…)

Ideas for Creative Agencies & Brands – #39

Laser Cut Summer BBQ Essentials

Laser Cut Beer Caddy Tom Keddie

As the days get longer and the hint of Summer warmth spreads its cheer, gathering together for a BBQ is a great way to reconnect with friends and family. For those who are hosting and also as gifts for (or from) the invited guests, laser cut BBQ tools and trinkets can make any event a memorable experience. Let’s take a look at a few BBQ ideas for creative brands and agencies this Summer.

Laser Cut Beer Sleeves

Pictured above, this handy beer caddy will enable up to 8 bottles or cans to be easily transported. The design makes use of the strengths of laser cutting, with interlocking components that require no adhesives and plenty of space to laser etch company, event or personalised details. Carting drinks from place to place doesn’t need to be an awkward balancing act – a laser cut beer caddy will get those drinks to your guests in style.

Laser Etched Cutting Boards

The broad, flat surface of a wooden cutting board or cheese platter is an ideal location for laser etched brand messaging. Adding details from an event, or personalising with quirky snippets and brand messaging will make this communal table item a memorable conversation starter or possibly even a desired keepsake. Examples: Dinner is Coming from Wicked Wooden Things, Mom’s recipe from 3D Carving, Lionel Richie from Darkling Designs 10.

Laser-Etched-Cutting-Boards

Laser Cut Bottle Opener

Having carted beers to all your guests, they will need a way to open the bottles. The profiles of openers are many and varied, and as these examples show, they are well suited to laser cutting. Whether you choose to have a little fun with the forms used (Beer & Friends from Hyde HousePorsche 911 classic from Racetrack Style); or incorporate the opener into an ingenious multi-tool (Hedgehog by Zootility Tools) or maybe go super-tiny like the Pangea Pico, the potential to get really creative with this simple and handy product is fantastic.

Laser-Cut-Bottle-Openers

 

Laser Cut Coasters

The surface and outline of the coaster can also be used for creating functional laser cut bottle openers, but if you’re not going that far, simply creating interesting shapes can be more than enough. Consider the laser cut and etched street map series titled I Kinda like it here by the National Design Collective, further quirky fun from Zootility and interlocking Penrose tile coasters from PhaseSpaceDesign in the Ponoko Showroom.

laser-cut-coasters

Each of these products present both an interesting form and a generous surface area where laser etching can be applied. As customised event collateral, they make for ideal promotional giveaways because they cleverly combine the feature of having fun with the function of being truly useful. All this happens while establishing further brand recognition and recall.

What other Summer BBQ Essentials 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 Cutting from a Galaxy Far Far Away

When The Force is strong

laser cut millenium falcon

When May the Fourth comes around each year, a whole galaxy of sci-fi fans kind of go nuts – well, more nuts than usual. It’s a fun time for these movie enthusiasts, and making models of the classic space vehicles from the original films can be a great way to share your enthusiasm with fellow fanatics.

Laser cutting is perfect for replicating the complex surface details of the iconic space vehicles, as has been well demonstrated by Thingiverse user Costaricaorca in the image above.

For others, the surface details take second place behind the actual shape of the vehicles. Once again, laser cutting provides an accessible way to replicate these forms and the following examples show how you don’t need much before it’s quite clear where the reference for the various machines comes from.

laser-cut-star-wars-thingiverse

Millenium Falcon by Killor; Waker by BillyMcCoy; and Star Destroyer with Tie Fighters by Breakfastsandwich

There are more like these to be found, uploaded by enthusiasts of all skill levels and experience to design community sites such as Thingiverse. Some have been made on laser cutters at local maker spaces, while others are zipped through during ‘spare time’ by employees lucky enough to have an on-site laser cutter at work. Another option that is accessible to all is to download files from Thingiverse and then have the parts cut in the material of your choice in the Ponoko Personal Factory.

May the fourth be with you…

 

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