Laser Cutter Projects

This project involved utilizing two different types of laser cutters—the Trotec Speedy 400 CO₂ laser and the FabLight FL4500 CNC fiber laser—to create a small birdhouse and a credit card-sized multi-tool, each demonstrating unique design principles and material considerations.

The birdhouse was designed to be assembled without fasteners or adhesives, relying solely on precisely engineered interference fits. This required careful iterative testing to fine-tune tolerances and ensure a secure, seamless assembly. The panels were cut from 1/8-inch plywood, demonstrating how 3D structures can be efficiently fabricated from 2D materials using tab-and-slot construction techniques.

For the multi-tool, I designed a compact and functional toolset in CAD, ensuring precise adherence to required tolerances. The final design, cut from blue anodized aluminum using the FabLight FL4500 fiber laser, featured nine integrated tools, including a small ruler, multiple standard wrench cutouts, a pry bar end, and circular marking holes. Attention to detail was crucial, as all dimensions were carefully verified to achieve a high-quality, functional end product.

These projects underscore the versatility and efficiency of laser cutting in rapid prototyping. Whether working with wood or metal, laser cutters enable the precise fabrication of intricate designs across various industries. Mastering this technology enhances my skills in digital fabrication, precision engineering, and iterative design, equipping me with valuable expertise in modern manufacturing techniques.