16/03/22
Background
The CCC project, short for Computer Controlled Cutting, involved designing a 2D or 3D everyday object lasercut out of either acrylic or MDF, with given constraints on the amount of material available for each. My material of MDF, chosen for its flexibility and aesthetics, had a constraint of a singular 150 x 300 x 3mm piece to create the entire object. Not only did I set out to design within these constraints, I also chose to design something functional and practical for my own personal use.
Ideation
I started this project by brainstorming different project ideas in order to figure out what I wanted to create. These lists stemmed from problems I identified that I wanted to solve, such as the coaster for the condensation coming from my glasses or the charging unit to help organize my cluttered desk.
After weighing the pros and cons of each option, I chose to make a charging unit for my phone and watch since I determined I would have enough material and would make the most use of such an item. I then chose to use MDF as the material since it would give me enough to work with while also providing the stability I would need for the unit.
Now that I had defined the problem I wanted to solve and the product that would achieve such a solution, my next step in the ideation phase was to start sketching and brainstorming potential designs. I first started researching different laser cutting techniques as well as charging units that currently exist to get a better idea of how I wanted my product to look like:
And then I began sketching to brainstorm possible solutions:
A common theme in my sketches is the use of kerf cuts (denoted by the curved surfaces covered in lines). Through my research, I discovered this technique could be used to create curved surfaces, an intriguing feature for what is normally a flat piece of wood. I decided I wanted to incorporate this into my design so I made sure to include curved surfaces in almost every sketch I created.
One idea I kept coming back to was the idea at the bottom of the top-left image shown above. I had multiple problems with this sketch, such as the question of where my watch would go or whether it used too much material, but it had the most potential for improvement and incorporated the kerf cuts in an interesting yet feasible way. This design would also be the most supportive for my phone. Thus, I chose this design to move on to the iteration phase.
Iteration
I began iterating by writing down constraints/requirements of the design that I needed to adhere to, such as phone and charger measurements. I then made sure the general shape of the design would fit within the material limits by modelling the shape with paper (as seen on the right). I also used this rough model to estimate the angle of the triangular sides and how my phone would line up against the edges. Thus, I created a rough sketch of the main layout of the design as well as some key dimensions.
From there, I focused on improving specific aspects of the design, such as the "stand" part that my phone would sit on or the hexagonal holes on the sides that could act as pen holders. I also added a small semi-circle at the back for my charger cord to go through, as well as a flat "lid" on the design for my watch to sit on. By focusing on the specific problems I had identified with this design in the ideation phase, I was able to effectively improve the design and move onto the next step in the iteration phase.
I started modelling the product in Rhino 7 in order to finalize the dimensions and better visualize how the components would fit together. I soon realized the dimensions I was using with my 3D model in Rhino didn't maximise the material available, so I used MakerCase to iterate on this aspect and find dimensions that worked with the material constraints. I also used MakerCase to import the pattern for the kerf cuts and "lid". Finally, I extracted the surfaces and curves from the model and fit them within a 15x30cm box to ensure it would meet the material constraints. Having proven this, I exported the pattern as an illustrator file for laser cutting.
Final Design
After adding text to the design in Illustrator and laser cutting the file, I assembled the product as seen below. I used a wet cloth to add moisture to the kerf cut section which helped the wood bend more easily. I then used wood glue to attach the "lid" to the top and taped it to keep the design in its final curved position. I slotted in the phone stand component (which fit perfectly, thus not requiring glue) and tested it out with my phone, watch, chargers and pens:
After the glue dried and the tape was taken off, I took my final photos of the finished product:
Reflecting on my final design, I noted a few features that I would have liked to include, such as a slot for my watch charger to sit on the top. I ran out of the time and materials that would have been necessary to do so, so if I were to iterate on this design again, I would try and optimise the material usage so that I could include more features.
Despite not being able to add everything I wanted to add to this design, I still think I learned a lot from it. The iteration process was particularly insightful for me: I learned the importance of going back to the original constraints/requirements (eg. the material limitations and the dimensions of my phone/chargers) to make sure the design still complies with them. I also learned about the importance of adding tolerances, especially with a physical product — although the phone stand slotted into the base component perfectly this time, it might not have done so in other instances due to differences in the laser cutter and/or material. If I were to repeat this design or send it to a manufacturer, I would add tolerances to certain parts to ensure they'll fit well together in the final product.
Overall, the lessons I learned from this project will go on to influence my design process by prompting me to generate more sketches, be more organised with my dimensions and add tolerances to my design. I've learned that the iteration phase requires a lot of organisation to keep track of every change made as well as the constraints the project has to adhere to. Thus, I'll strive to be more organised throughout the design process, especially during the iteration phase, in order to produce the best possible design for the problem at hand.
References
10 Great Laser Cutter Projects You can make at home - xtool. (n.d.). Retrieved March 16, 2022, from https://www.xtool.com/blogs/xtool-academy/10-great-laser-cutter-projects-you-can-make-at-home
12 wood laser cutting projects and ideas. Bitfab. (2020, September 22). Retrieved March 16, 2022, from https://bitfab.io/blog/laser-cutting-projects-wood/
Carmel. (2021, June 23). Laser Cut Wood: The 10 best projects! Sculpteo. Retrieved March 16, 2022, from https://www.sculpteo.com/en/3d-learning-hub/laser-cutting/best-laser-cut-wood-projects/
Cell phone stand iwatch holder for Apple Watch Charger, nightstand cradle desk dock office accessories compatible with iPhone 11 Pro XS Max XR X 8 7 6 Plus, iwatch 12345 and more Android phones. Walmart.com. (n.d.). Retrieved March 16, 2022, from https://www.walmart.com/ip/Cell-Phone-Stand-iWatch-Holder-Apple-Watch-Charger-NightStand-Cradle-Desk-Dock-Office-Accessories-Compatible-iPhone-11-Pro-Xs-Max-XR-X-8-7-6-Plus-123/600017801
Hollander, J. (n.d.). Easy Laser Cut Case Design. MakerCase. Retrieved March 16, 2022, from https://en.makercase.com/#/kerfbox
Horn, L., & Mitchell, R. (2021, November 18). 150 amazing laser cutter projects and ideas to inspire you. Ponoko. Retrieved March 16, 2022, from https://www.ponoko.com/blog/design-ideas/laser-cutter-projects-ideas/
Laser Cutter: "Kerf-cut" techniques (bending wood). IDEA. (n.d.). Retrieved March 16, 2022, from https://ideaexchange.org/oldpostoffice/guide/kerf-cut-techniques-laser-cutterbending-wood
Porterfield, A., & Instructables. (2017, October 15). Curved Laser Bent Wood. Instructables. Retrieved March 16, 2022, from https://www.instructables.com/Curved-laser-bent-wood/
Shopee.ph. (n.d.). Retrieved March 16, 2022, from https://shopee.ph/Wood-Watch-Rack-Phone-Stand-Holder-for-Apple-Watch-IPhone-i.50707001.823522578
Comments