MSRaynsford

While making samples for the vanillabox I was keen to experiment with new/cheap materials. I modelled this vase in 3D and sliced it with 123D make (which now appears to have gone), I cut each layer in corrugated card. I actually started life as a lampshade but it didn't let enough light through so when it was flipped upside down I realised it would make a nice vase. The petals for the flowers were all cut from crepe paper using a very low power so as to minimise the burning around the edges. The petals were wrapped with floral tape and wire to create the flower shapes. At the maker faire we had to label the item because people didn't realise the flowers were laser cut.

The kids grew some pretty epic sunflowers over the summer and we harvested the seeds to grow some more next year (third year running actually). We decided to share the seeds with people for Christmas and I laser cut a load of packets to go with them. The details were printed onto the paper with a standard laser printer, as you can see from the close ups the cut lines were incredibly close to the printed lines. The trick is to let the laser cut a hole to show you where to put the sheets of paper.

Just like last time our tent needed a big sign to go on the outside, this one was cut from 3 ply corrugated card that was 20mm thick. It made the letters stand out quite well. I didn't have room for the shark and the laser beam so when Dominic complained that it was left off I improvised. The night air gave it some serious droop but it made me laugh anyway.

The big thing occupying my time currently is the vanilla box. I'm slightly outside my comfort zone with metal work but it's always good to learn new skills. We're getting the box CNC cut so I can already do the drawings but I'm learning about bend radii and powder coating etc. The case is made from sheet metal with bends in appropriate places and I'm able to make prototypes out of paper to make sure it all fits together correctly. Having these physical models really helps to visualise where everything is going to go.

Prototypes for a friend who is play testing a game and wanted something more substantial that paper cut outs. The tokens were made by colour printing labels and putting them onto greyboard before cutting the individual tiles out. It's another alignment trick and it was done in two stages. First the outline was cut, the sticker was applied and then it was put back into the hole before cutting the individual tokens out. Cut the outline from the greyboard Cut down the lable and stick it to the greyboard Put the sticker back into the hole  Cut the individual tokens out

This project was done in a rush at the beginning of July according to the time stamps on the photos. Eli wanted to go to a party dressed as Hiro so I quickly made up a Pepakura Helmet for him the night before the party. Some repainted knee and elbow pads and we're mostly there. The helmet was printed on our colour printer and then cut using the laser and a few alignment tricks. I have written an instructable about the process but it boils down to letting the laser cut a hole the same size as your item and then putting the item into the hole. This method solves most alignment issues. ( instructable and all files here ) We're going to need a bigger Baymax

I was inspired by George Hart  to make some kind of large sculpture that could be assembled at a maker faire maybe with half a dozen people helping to build it. I designed this one on a 3D model, it's made from 60 identical pieces that all interlock. The main issue is that it doesn't take photo easily. We went to Manchester Makefest and made one from corrugated card that was 5 times larger, it took most of the morning to assemble, we made a second one that was a mirror image but then we lost all the photos we took of it. If you were at Manchester Makefest and you happened to get a picture then we would love to see it, otherwise this is destined to remain a single dull post. The sphere itself was pretty easy to build (even with a hangover), I'll happily share the file if people are interested. If I were to do it again I would try to find away to add another linkage between the parts, this whole thing feels a bit like a ball within a ball and it could do with a few m...

It wasn't just bunting I made for Nan, I was also encouraged to make a present too, Kim pointed me towards nice family trees, went out and hunted a picture frame and even bought me black card. I just drew and cut and assembled. The black silhouette is a fairly standard card cut out, but I replaced the mdf backing found on most frames with a perspex backing to make the frame see through and the whole thing pop out.

While I was busy making useless machines in the garage today the rest of the family was inside making bunting for Nan's 80th Birthday party (the kids loved it). Not wanting to be totally left out I rolled in at the last moment with half a dozen laser cut flags to be added to the mix. Clearly a lot more effort and love went in to the hand crafted flags but I guess we all have our own skills and Nan will appreciate the thought.

While trying to build the skin for the inside of my hopper  I needed to cut a lot of paper to the right size. I perforated the sheets to make them fold and fit the hopper perfectly but they were taking 5 minutes a time to cut, 5x 32 makes for a long and tedious evening. I decided to try and cut multiple layers at once. It's been a very long time since I last tried this. Previously I tried it with my HPC 3020 which made a real mess of it, the Just Add Sharks lasers have better air assist and better extraction so I was optimistic.  I was able to cut through 3 sheets at once, but it definitely had some issues. The top layers of paper were actually blown around by the powerful air assist. This could be easily remedied with appropriately placed magnets. The bigger issue is that as you get to the bottoms layers there is increased smoke staining. So this method is really just quick and dirty and sometimes that's all you really want but if you're trying to make anyt...

I saw these HyperQBS from Geobender.com and thought they were very cool so I decided to make one. A 3D model was made, flattened using Pepakura and Laser cut for quick assembly, then it was glued and taped to turn it into a hexaflexagon thingy, I even wrote an instructable about it if you'd like to make your own.

I gave a little talk at Starbase Leicester last night about how modern manufacturing had reached the hobbyist market and that local hackspaces were now filled with CNC mills, laser cutters and 3D printers amongst other useful things. I tried to tie this all in to the cosplay that they were doing and I hope it filled them with ideas about what is actually possible with access to the right tools. I showed some of my laser cut pepakura but I also drew and laser cut a paper version of a companion cube. The plan was that people would help me assemble it and the space would get to keep it. In the best laid plans of these things that never really happened so I came home with a box full of paper parts. While watching some TV I thought I would assemble it. After a few hours of show and only having one corner made I realised that I just don't have time for this kind of thing anymore. If I'm invested in a project I will make the time but something disposable like this object would b...

I met Sarah  through Leicester hackspace, she's done some really amazing paper cuts but now she is trying to find a way to cut them automagically instead of doing it all by hand. We ended up talking about vinyl cutters vs laser cutters and I came away to test patterns on the laser to see if they were possible. They cut really well with minimal burning and soot. The items themselves are mounts to go on photos and I can see them selling like hot cakes.

I had to make this one twice as the first one wasn't actually big enough for my head. It's the same deal as the last head , pepakurad 3D model of a rabbit. They take so long to cut and assemble even with a fancy laser, that's what makes them good weekly projects. ( svg here )  34 Projects/43 Weeks