LASER MANUAL FOR THE MODEL MAKING WORKSHOP OF THE INSTITUTE FOR ARCHITECTURE archi POOL // MODEL WORKSHOP 1PAGE

L A S E R M A N U A L F O R T H E M O D E L M A K I N G W O R K S H O P O F T H E I N S T I T U T E F O R A R C H I T E C T U R E

The laser cutting machine at the model building workshop is an open source cutter and has specific requirements for its use. The following instructions in this manual should be considered in particular. Regarding the preparation of your files, please make sure to use the said software (Rhino and Inkscape) to create DXF and SVG files, and not alternatives which may also seem capable of doing so.

Generally, no appointments are being issued. Laser jobs will be listed, once the materials and files have been handed in. Waiting times of 2-3 days have to be taken into account during periods of deadlines (mid-term and final presentation).

The laser cutter uses high-energy light, which is focused by a lens. While cutting, material is being burned. This results into a small gap between 0,1 - 0,3 mm, de-pending on the power of the laser.

The focus of the laser beam is subject to the material height. For a consistent en-graving and cutting quality the material should be as flat as possible. If this is not the case and cannot be prevented, make sure to keep a distance of 10 mm to the material edge. This space is need for placing weights.

For engraving acrylic glass, it is essential to use cast/poured acrylic glass (abbr.: GS). Extruded acrylic glass (abbr.: XT) cannot be engraved.

Special comments:

1. A distance of at least 1 mm must be maintained between objects.

2. Acrylic glass will be slightly raised on the laser cutter surface. In order to ena-ble this, make sure to keep a space of 5 mm to the material edge clear. Furthermore large sheets should have strip cleared lengthwise in the centre of the sheet for more support.

3. Some lasered lines may appear shaky. This is due to the interplay of the mo-tors and toothed belts and cannot be altered.

4. Please keep in mind that the laser cutter has its limits with cutting small ob-jects. (In case of uncertainty, a test print on paper with a line weight of 0,2 mm is recommended.)

LASER MANUAL FOR THE MODEL MAKING WORKSHOP OF THE INSTITUTE FOR ARCHITECTURE archi POOL // MODEL WORKSHOP 2PAGE

A PREPARING A DXF FILE IN RHINO

1. Define the point of origin (0,0,0) and draw a rectangular border measuring 1200x600 mm. Your sheet cannot exceed this size.

2. Draw another frame in the size of your material and place it in the top left corner of the border.

3. Place your drawing within the material frame. Lines should not touch the initial border frame, make sure that these are offset by 0,3 mm. Offset a copy of the material frame by 0,3 mm inwards with the command “_Offset”. Trim all exceeding lines with the command “_Trim” and delete the frame again afterwards.

4. For cutting acrylic glass, ensure a distance of 5 mm to the material border.

5. For almost flawless results, the material has to stay intact as long as possi-ble during the laser cut. In this respect the cutting order has to be ensured through the right distribution on layers with specific colours. Keep in mind that engraving takes place first, followed by all inner contours and com-pleted with the outer contour. Use this list for layer structure and colour mapping:

ENGRAVING 1 Red R=255 G=0 B=0 2 Orange R=255 G=127 B=0 CUTTING OF INNER CONTOURS 3 Green R=0 G=255 B=0 4 Cyan R=0 G=255 B=255 5 Blue R=0 G=0 B=255 6 LightGrey R=230 G=230 B=230 7 Grey R=190 G=190 B=190 CUTTING OF OUTER CONTOUR 8 Magenta R=255 G=0 B=255

LASER MANUAL FOR THE MODEL MAKING WORKSHOP OF THE INSTITUTE FOR ARCHITECTURE archi POOL // MODEL WORKSHOP 3PAGE

A PREPARING A DXF FILE IN RHINO

6. Overlapping lines have to be removed (double lines, short lines on long lines) Therefor edit every layer separately. Use the command “_Explode” to explode all selected lines. Afterwards klick anywhere in the drawing to sur-face - no lines should be selected. Use the command “_SelDup” to select all double lines and delete these. Now join all lines again with the command “_Join”. Repeat this with all other layers.

7. Ensure that all Lines are joined to Polylines.

8. Disassemble all blocks or symbols. Use the command “_ExplodeBlock”.

9. Disassemble all groups. Use the command “_Ungroup”.

10. Usually text elements are set up with contours and hatches. Hatches can-not be laser cut. Therefor select all text elements with “Edit” “Select Objects” “by Text” and disassemble with “_Explode”. Through “Edit” “Select Objects” “by Hatches” delete all hatches. Now Join all single lines to polylines.

11. Choose Front window and check, if the drawing is planar on the CPlane (z=0). If this is not the case, use the command “_ProjectToCPlane” on selected Objects to ensure the drawing is two-dimensional.

12. If using grids, distribute horizontal and vertical lines to separate layers. Example: Engraving: horizontal lines – Layer Red vertical lines – Layer Orange Cutting: horizontal lines – Layer Green vertical lines – Layer Cyan

LASER MANUAL FOR THE MODEL MAKING WORKSHOP OF THE INSTITUTE FOR ARCHITECTURE archi POOL // MODEL WORKSHOP 4PAGE

A EXAMPLES

Material: 2mm grey cardboard

1. Engraving and final cut for the outer contour 1 Red (1) engraving 1 =pass1:2000mm/min:8%= 2 Magenta (8) outer contour =pass2:2000mm/min:70%=

2. Two different engravings and final cut for the outer contour 1 Red (1) engraving 1 =pass1:2000mm/min:8%= 2 Orange (2) engraving 2 =pass2:2000mm/min:8%= 3 Magenta (3) outer contour =pass3:2000mm/min:70%=

3. Engraving, two cuts for inner contours and final cut for the outer contour 1 Red (1) engraving 1 =pass1:2000mm/min:8%= 2 Green (3) inner contour 1 =pass2:2000mm/min:70%= 3 Cyan (4) inner contour 2 =pass3:2000mm/min:70%= 4 Magenta (8) outer contour =pass4:2000mm/min:70%=

4. Four cuts for inner contours and final cut for outer contours 1 Green (3) inner contour 1 =pass1:2000mm/min:70%= 2 Cyan (4) inner contour 2 =pass2:2000mm/min:70%= 3 Blue (5) inner contour 3 =pass3:2000mm/min:70%= 4 LightGrey (6) inner contour 4 =pass4:2000mm/min:70%= 5 Magenta (8) outer contour =pass5:2000mm/min:70%=

example 4

example 2

example 3

example 1

LASER MANUAL FOR THE MODEL MAKING WORKSHOP OF THE INSTITUTE FOR ARCHITECTURE archi POOL // MODEL WORKSHOP 5PAGE

B EXPORT FROM RHINO

1. Each material sheet which is supposed to be lasercut needs its own file. Therefor select the sheet and export with “File” “Export Selected”. Choose DXF as file type.

2. Name your files accordingly: material_thickness_number_quantity example: greycardboard_1-5mm_01 mdf_4mm_01_2x acrylicglass_2mm_01

3. DWG/DXF export options Choose export scheme “Laser”. If non-existent, choose “2004 Lines (Rhi-no 5)/ 2007 Lines (Rhino 6)” from the list and edit the settings as so: General: AutoCAD Version = Release 14 Project to Plane = CPlane Curves: Arc = Arc Save these settings as “Laser” for later use.

LASER MANUAL FOR THE MODEL MAKING WORKSHOP OF THE INSTITUTE FOR ARCHITECTURE archi POOL // MODEL WORKSHOP 6PAGE

C CONVERTING DXF INTO SVG WITH INKSCAPE

1. Open the provided template “Inkscape Vorlage.svg” with Inkscape soft-ware (freeware). You can find the template file on archi-pool und Werkstät-ten website in the sector scripts and downloads. https://www.architektur.tu-berlin.de/menue/it_service/cip_pool_architektur/ https://www.architektur.tu-berlin.de/menue/fachgebieteinstitutsrat_beauf-tragtewerkstaetten/werkstaetten/

2. Import the DXF file with “File” “Import”. DXF Input window opens. Untick the box “Use automatic scaling to A4. From Version 0.92 onwards tick the box “manual scale”.

3. The imported drawing is grouped. Select all lines with one klick on the drawing. Drag the drawing the left upper corner. Place it so that a small white square remains visible - the centre axis of the line has to stay within the drawing boundary. For accurate placement it is fundamental that the inital frame of 1200x600 mm has been drawn and exported. Inkscape automatically assigns line weights. This value may vary depend-ing on the software version. It only serves as a visualisation and is not coherent to the thickness of the laser cut line. Once the drawing is selected in Inkscape, the following values appear in the toolbar: until Version 0.91 B = 1200,282 H = 600,282 from Version 0.92 B = 1200,265 H = 600,265 The decimal values ,282 or ,265 correspond to the line thickness, therefore has to be 1200x600 mm large. Values for Placement value for X = – 1/2 * line thickness value for Y = 610 – 600 – 1/2 * line thickness

LASER MANUAL FOR THE MODEL MAKING WORKSHOP OF THE INSTITUTE FOR ARCHITECTURE archi POOL // MODEL WORKSHOP 7PAGE

C

MATERIALS AND THICKNESS OF MATERIAL

solid wood max. 8 mmmedium-density fibreboard max. 8 mmchipboard max. 8 mmmultiplex board max. 10 mmplywood max. 10 mmblockboard max. 10 mmcardboard max. 6 mmcorrugated cardboard max. 10 mmacrylic glass (polymerised GS, extruded XT) max. 10 mmpolyurethane max. 5 mmpaperleathercellular/foam rubberfabric/textiles

COSTS

30 Cent/min // 18 Euro/hour Arising expenses are calculated from the net cutting time not the absolute total processing time. Approximate costs can be estimated as so: In Rhino select all line which are sup-posed to be laser cut. Apply the command “_Length” to evaluate the total length. The cutting time can be determined with the length and the feed rate, which has been established before. However, it has to be considered that the free travel in between objects is not taken into account and may increase the laser cut time considerably.

CONVERTING DXF INTO SVG WITH INKSCAPE

4. A description field with passes can be found in the botton right corner of the worksheet. A single pass has to be assigned to every layer with colour to ensure correct order of cutting. Use the same order as in the list for colours. Insert the values for feed rate and power regarding the choice of material and its specific thickness. Use the given chart. Only change the numerical values, the code has to stay intact. Delete all redundant text lines.

5. Save the file with the same file name chosen for the DXF, only this time use “Inkscape SVG” file type.

LASER MANUAL FOR THE MODEL MAKING WORKSHOP OF THE INSTITUTE FOR ARCHITECTURE archi POOL // MODEL WORKSHOP 8PAGE

alle wood types,weak

1-19 mm 2000 mm/min 4-6 %

alle wood types,average

1-19 mm 2000 mm/min 7-10 %

alle wood types,strong

1-19 mm 2000 mm/min 11-14 %

material thickness freed rate power

MDF black,weak

1-19 mm 2000 mm/min 5-7 %

MDF black,average

1-19 mm 2000 mm/min 8-11 %

MDF black,strong

1-19 mm 2000 mm/min 12-15 %

cardboard,weak

1-10 mm 2000 mm/min 4-6 %

cardboard,average

1-10 mm 2000 mm/min 7-10 %

cardboard,strong

1-10 mm 2000 mm/min 11-14 %

acrylic glass (GS),weak

1-10 mm 2000 mm/min 4-6 %

acrylic galss (GS),average

1-10 mm 2000 mm/min 7-10 %

acrylic glass (GS),strong

1-10 mm 2000 mm/min 11-14 %

ENGRAVING

MDF black/brown 1,0 mm 2000 mm/min 55 %

MDF black/brown 1,5 mm 2000 mm/min 60 %

MDF black/brown 2,0 mm 2000 mm/min 65 %

MDF black/brown 2,5 mm 1850 mm/min 70 %

MDF black/brown 3,0 mm 1700 mm/min 75 %

MDF black/brown 4,0 mm 1400 mm/min 80 %

MDF black/brown 5,0 mm 900 mm/min 85 %

MDF black/brown 6,0 mm 600 mm/min 90 %

MDF black/brown 8,0 mm 450 mm/min 100 %

plywood 1,0 mm 1800 mm/min 55 %

plywood 1,5 mm 1800 mm/min 65 %

plywood 2,0 mm 1700 mm/min 75 %

plywood 2,5 mm 1400 mm/min 85 %

plywood 3,0 mm 1000 mm/min 85 %

multiplex 2,0 mm 1700 mm/min 60 %

multiplex 3,0 mm 1700 mm/min 70 %

multiplex 4,0 mm 1400 mm/min 80 %

multiplex 6,0 mm 1000 mm/min 80 %

multiplex 8,0 mm 400 mm/min 100 %

solid wood 2,0 mm 1700 mm/min 60 %

solid wood 3,0 mm 1700 mm/min 70 %

solid wood 4,0 mm 1400 mm/min 80 %

solid wood 6,0 mm 1000 mm/min 80 %

solid wood 8,0 mm 400 mm/min 100 %

plywood (birch) 4,0 mm 1400 mm/min 80 %

plywood (birch) 6,0 mm 1000 mm/min 80 %

plywood (birch) 8,0 mm 700 mm/min 100 %

material thickness feed rate power

CUTTING OF WOOD MATERIALS

LASER MANUAL FOR THE MODEL MAKING WORKSHOP OF THE INSTITUTE FOR ARCHITECTURE archi POOL // MODEL WORKSHOP 9PAGE

grey cardboard 1,0 mm 2000 mm/min 50 %

grey cardboard 1,5 mm 2000 mm/min 60 %

grey cardboard 2,0 mm 2000 mm/min 70 %

grey cardboard 2,5 mm 1850 mm/min 85 %

grey cardboard 3,0 mm 1700 mm/min 85 %

finnboard 1,0 mm 2000 mm/min 50 %

finnboard 1,5 mm 2000 mm/min 60 %

finnboard 2,0 mm 2000 mm/min 70 %

finnboard 2,5 mm 1850 mm/min 85 %

finnboard 3,0 mm 1700 mm/min 85 %

bristol board 1,0 mm 2000 mm/min 45 %

bristol board 1,5 mm 2000 mm/min 55 %

bristol board 2,0 mm 1800 mm/min 65 %

bristol board 2,5 mm 1800 mm/min 75 %

bristol board 3,0 mm 1700 mm/min 85 %

corrugated board 3,0 mm 2500 mm/min 50 %

corrugated board 6,0 mm 1200 mm/min 80 %

material thickness feed rate power material thickness feed rate power

CUTTING OF CARDBOARDS

acrylic glass (GS/XT) 1,0 mm 1800 mm/min 60 %

acrylic glass (GS/XT) 2,0 mm 1400 mm/min 80 %

acrylic glass (GS/XT) 3,0 mm 1000 mm/min 90 %

acrylic glass (GS/XT) 4,0 mm 800 mm/min 90 %

acrylic glass (GS/XT) 5,0 mm 600 mm/min 100 %

acrylic glass (GS/XT) 6,0 mm 400 mm/min 100 %

acrylic glass (GS/XT) 8,0 mm 200 mm/min 100 %

acrylic glass (GS/XT) 10,0 mm 100 mm/min 100 %

cellular/foam rubber 2,0 mm 2000 mm/min 40 %

polyurethane (600) 2,0 mm 1800 mm/min 60 %

CUTTING OF SYNTHETIC MATERIALS

LAYER AND COLOUR ORDER

ENGRAVING 1 Red R=255 G=0 B=0 2 Orange R=255 G=127 B=0 CUTTING OF INNER CONTOURS 3 Green R=0 G=255 B=0 4 Cyan R=0 G=255 B=255 5 Blue R=0 G=0 B=255 6 LightGrey R=230 G=230 B=230 7 Grey R=190 G=190 B=190 CUTTING OF OUTER CONTOUR 8 Magenta R=255 G=0 B=255