Laser Cutting

In this blog, I will be documenting my experience with the laser cutter🔍. 

Learning laser cutting was easy yet challenging in a way that I do not have to design but I had to write an SOP to use for my competency test by simplifying the existing step-to-step guide into 3 pages which is challenging as I had to visualise the procedure in our brain🧠. 

On this page, I will describe:
1. The 4 important hazards associated with the operation of laser cutting machines 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 of the operation of the UNIVERSAL laser cutter, consist of:
        3.1 Starting the compressor, turning on the laser cutter machine and fume extractor.
        3.2 Importing a .DXF file to CorelDraw and modifying the lines/fill for cutting and engraving.
        3.3 Sending the CorelDraw drawing to laser cutter software and setting the laser cutter power, speed, and PPI in the software.
        3.4 Starting the job on the laser cutter machine.
        3.5 DOs and DONTs when there’s flame/fire on the material being cut.

4. My Learning reflection on the laser cutter activities.



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

Hazards

Safety control measures

Pictures to support the explanation

1. Fire🔥


Risk of fire from cutting materials.


Risk of fire from dirt & debris. 

Engineering control:

  • Safety interlocked lip feature on the machine to prevent unsafe operation. For small flames, the user can lift the lid and blow air to extinguish the flame. The laser will stop operating once the lip is lifted. For bigger fires, a fire extinguisher is available. 


  • Air assist system minimises heat around the laser head, removing debris from around the contact point and preventing burning.  


Administrative:

  • Warning signs are placed to inform about the risk of exposure during use.


  • Proper training & competency test was given to the user to ensure they understood the hazards and procedures.


  • Fire extinguisher🧯 is placed nearby.


  • Approved materials ✅list is placed near the workstation. To prevent students from laser cutting incorrect materials and causing unwanted flames/ fires.

  







2. Health 💪


Risk of highly toxic fumes inhalation from cutting material.

Engineering control:

  • A fume extractor is installed to remove toxic vapours. 

3. Laser light😱


Risk of eye damage👀 from the invisible high-energy laser beam.

Administrative: 

  • Warning signs are placed to inform about the risk of exposure during use.


  • Proper training & competency test was given to the student to ensure that they are aware of the hazard and the operating procedure. 

4. Tripping 😬


Risk of tripping over plugs and cables. 

Engineering control:

  • Cables and plugs are well organised such that it is positioned to prevent tripping or snagging. 



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

Material

Photo of material

1. Wood (plywood, natural wood & MDF)

Plywood:


Natural wood (balsa wood):



2. Acrylic 

3. Cardboard


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

Material

Photo of material

1. PVC

2. Metal

3. Foam



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

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

Steps and description

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

  1. Switch on the power for the fume extractor. Do not touch the laser cutter.


3.2 Importing a .DXF file to CorelDraw and modify the lines/fill for cutting and engraving.

Steps and description

  1. Import a file into Corel-Draw.


Select File > Import > Select your .DXF file and press import


  1. Double click “Outline Pen” located at the bottom right-hand corner of Coral-draw.

  1. Change colour to “RGB: Green” and line weight to “hairline” for design. Once done, click ok. Green borders will appear. (for engraving) 


  1. Change colour to “RGB: Red” and line weight to “hairline” for design. Once done, click ok. Red borders will appear. (for cutting)


  1. Change colour to “RGB: Green”. Double click on “Fill Tool” to change the colour to Green for text. Once done, click ok. Green borders will appear. (for engraving) 



Vector Cut

Vector Engrave (scoring)

Engrave

Colour

RED

GREEN

GREEN

Line Weight

Hairline

Hairline

-

Fill

-

-

GREEN


R: 255

G: 0

B: 0

R: 0

G: 255

B: 0

Text

R: 0

G: 255

B: 0

Images 

Need to convert to greyscale.

- bitmaps > mode > greyscale


Make sure black is in RAST mode in print!


On clear acrylic, need to invert colour

- effects > transform > invert colours 


  1. Ensure red and green borders are presented. 


If borders remain greyscale. No cutting and engraving will happen during laser cutting.




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

Steps and description

  1. Once checked, sent the design for laser cut by clicking on File > Print.



  1. Click on the Cogwheel for settings located beside the word “Printer” on the “Print page”.

  1. On the universal’s material setting page. Click on “Load” for more material settings.

  1. Select the presets that match your material type and thickness and select “Open”

  1. Ensure the “Mode” for the colour red and green is set to “Rast/Vect”. 


If it is set to “Skip”, change the “Mode” setting to “Rast/Vect” at the dropdown menu for “Mode” located at the top right-hand corner of the page. 

  1. Change Power, Speed, PPI (pulses per inch) and Z-axis to an appropriate value. (if applicable) 

  1. Once done, click ok. Click “Print” 


3.4 Starting the job on the laser cutter machine.

Steps and description

  1. Click on the UCP (universal control panel) icon on the taskbar.

  1. Click on the “Power” button [1] to activate the laser cutter located on the top right of the control panel. Note, do wait until the “Play” button [2] changes colour from grey to green and no cutting happens at this stage. 


If the “Play” button [2] is green before activation of UCP, do deactivate and reactivate it again by clicking on the “Power” button [1] twice.

  1. Click “Focus view”.

  1. Verify that the design to be cut/ engrave is within the cut zone by placing the blue cross between the gaps and looking at the head of the cutter. If the design falls outside of the cut zone, relocate the model.


Relocation of the image either shifting it manually or adjusting the x-axis and y-axis value located on UCP.


  1. Click on the “Estimate time Button” and press the “Start” button to check for the timing.


Note, this does not start the Laser cut.

  1. Once done, close the lip of the laser cutter gently.

  1. Press either the “Play” button [2] on UCP or the Physical button on the Laser cutter.



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

DOs 

Do lift the lip to blow off the flame to put out the fire. If the fire is negligible

Do remove material from the laser cutter and place it on the floor and step on it to put out the fire. If the fire is unable to blow off. 

Do hit the emergency button to cut power to the laser cutter located near the door. Find the closest fire extinguisher and put it out. Alert the staff by shouting for help. If the fire is uncontrollable. 



DONTs

Do not stare at the beam during cutting. Only monitor the cut by glancing at it. 

Do not leave the machine unattended during cutting. Inform a friend who is certified in the laser cutter or press the “Pause” button on the UCP and inform the staff




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


Laser cutting was fun😀 as I get to explore something new and it is definitely easier than operating 3D printers in terms of their waiting time🕑, preparation required📓 and appearance👀.  



Waiting time for a simple design 

Preparation required 

Appearance 

3D printer 

Longer 

A lot of things to prepare 

3d models 

Laser cutter 

Shorter 😆

Minimal things to prepare 😄

2d models 


Linking back to ICPD, I know that laser cutting is taking material away while 3D printing is adding material. After having the chance to use both methods. With 3D printing, I am able to print a wide range of shapes with different geometrical shapes and since it is addictive manufacturing, I am able to prototype complex designs. With laser cutting, I can use different materials, not just plastic, and it’s fast to cut. 


Laser cutting has ignited my passion😁 to create more designs as compared to 3d printing as it is really simple to import the design, change the settings on UCP and cut the material. In Makerspace or fab lab most settings are already preset for us like the picture shown below unless we want to customise the settings for a different colour label then we can just change accordingly but generally we will only use red and green labels. 

I recalled that for 3d printing, I have to spend at least 45 mins😭 to heat up the filament before I can even insert the filament into the loader and start printing. Furthermore, many problems happened when I was 3d printing. E.g., my filament snapped twice😤, warping happened👎 and the infill pattern was messy and incomplete😰 which was so frustrating. Hence, I was really thankful that my laser-cutting process was smooth with no hiccups💗.