Fabrication Methods

Laser cutting is a method of projecting precise, two-dimensional vector geometry onto planar material sheets using a 2-axis operation process.

These operations include:

1. Cutting vector lines to obtain shapes with straight and/or curved edges

2. Etching vector lines/patterns onto the material surface

3. Rastering filled areas to create patterns on the material surface

A combination of these operations may be processed in a single job to create intricate forms and surface patterns.

When to apply Laser Cutting?

For quick turn around time and efficient means of fabrication, laser cutting allows the digital unrolling of three-dimensional objects into two-dimensional components for physical reconfiguration.

It allows for a simple and cheap method of fabrication to be processed with the potential to obtain intricate details and forms if planned appropriately. Laser cutting is perfect for small scale model making, intricate panelling and/or layering. The laser cutter also enables possibilities of material manipulation such as bending or folding depending on what operations were used.

The Fab Lab stocks a selection of materials that are ideal for use with the laser cutter. Outsourced or unfamiliar materials may be processed provided they meet certain criteria (as approved by Fab Lab staff).

Post-Processing

Typically, laser cut jobs will require assembly after being cut.

Depending on the material selection, paint may be applied, and sanding or rubbing isopropyl alcohol will reduce visual effects of burn marks that may be left over from cutting.

Laser cutting is a method of projecting precise, two-dimensional vector geometry onto material sheets, with the intent of processing a 2-axis operation (x,y) The Kern metal laser cutter also carries the option to use a rotary adaptation, allowing for rotary cutting of tubing (a-axis).

These operations include:

1. Cutting vector lines to obtain shapes with straight and/or curved edges

2. Etching vector lines/patterns onto the material surface

3. Rastering filled areas to create patterns on the material surface

A combination of these operations may be processed in a single job to create intricate forms and surface patterns.

The metal laser cutter adds the further capabilities of cutting thicker materials, metals and pipe or tubes on its chuck rotary stage.

The sizing of the metal laser bed allows for larger scale cutting while its powerful laser can be controlled through carbon dioxide, oxygen or nitrogen cutting.

Post-Processing Metal Laser Cuts

Post-Processing metal cuts may be done in the Timber Workshop and/or the Metal Workshop. These can vary from sanding/grinding rough edges to polishing surfaces and welding pieces together. Utilisation of this machine provides the opportunity to fabricate strong, working parts and/or large-scale model components.

Laser cutting may be used for both prototyping, due to its quick turn around and low cost fee, and final model construction due to its accurate detailing.

A CNC router is a large and powerful milling machine which can be precisely controlled via computer software. It can cut and mill various hard materials, such as wood, composites, aluminium, plastics, and foams.

Using a physical tool bit, the CNC router removes material from stock (material) in order to shape a part. The machine is navigated through of 'G-code', a string of operations and locations in Cartesian space (x,y,z). The benefit of using a physical tool bit, is the variability of cutting operations that the CNC machine can operate. These range from thickness, to the geometry of the bit such a V-milling, Ball nose, Flat down and up cutters.

The range of tooling options combined with the large operational size of the machine bed allows the fabrication of 2D and 3D processes at an industrial scale. The CNC can be used to prototype medium to large parts, testing tolerances as well as produce final furniture quality components. While surface/topography milling is lengthy and costly, therefore is done as a final product to ensure both quality and accuracy.

The dimensional constraints of a physical cutter (as opposed to something like a laser cutter) mean than ultra fine levels of detail are generally not achievable. However, strategies line engraving are still possible.

With materials outside the Fab Lab's stock list, generally hardwood, post-processing of stock material is required through either lamination or thickening depending of the object file. This can be done in the Timber Workshop.

Post-Processing CNC Machine Cuts

Edge finishes of CNC milling will be precise, depending on the intended detail of the object. These types of cuts however, can be further processed in the timber workshop, either sanding and applying finishes on the piece.

3D printing is a process of making three-dimensional solid objects from a digital file. The object is created using an additive process where successive layers of material are laid down until the object is created. Each of these layers can be seen as a thinly sliced horizontal cross-section of the eventual object.

We offer two types of 3D printing at Fab-Lab:

1. Resin (SLA) printing:

   Stereolithography (SLA) 3D printing is the most common resin 3D printing process that has become vastly popular for its ability to produce high-accuracy, isotropic, and watertight prototypes and end-use parts in a range of advanced materials with fine features and smooth surface finish.

1. FDM printing: FDM printing is an anisotropic additive fabrication method which deposits consecutive layers of plastic filament to great 3D objects. FDM printing is effective for a range of object types. FDM is cost effective, being only $0.15 per gram when processing with the Fab Lab.

Follow the link below for more information on each of these 3D printing technologies or to prepare and submit your job:

The Machine Workshop is a hands-on maker space.

Providing access to all key tools, technology and training needed to build designs, the workshop allows students to work with materials such as timber, foam, plastics and aluminium on a range of machines. These may include the band saw, drop-saw, thicknesser, routers and various hand tools.

Timber Workshop

Click here for more Timber Workshop Information:

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Metal Workshop

Click here for more Metal Workshop Information:

GitBook