Market Day 2025 Laser Cut Night Light: Revisited

 

In March last year we were looking at developing the idea of combing the school laser cutter with a set of LED lights to create either a night light or some kind of illumination.     

This year as part of Market Day 2025 one of our groups was looking for an example of personalisation, that could be applied to a project, and we have already a group creating a version of Minecraft themed night light.   We applied the same basic principals to this design, the original of which you can see detailed here on this blog from March of last year.

As this is a prototype version of this print measures 100mm square and is 120mm high.    The current MDF is 6mm thick.    The light affect has been created by using a set of relatively inexpensive fairy lights, which means that the entire unit can be produced for under $5.

The next phase is of course to identify the personalisation of the unit and how that can occur.   The answer to this of course lies in the 3D Printing for the names.   It is conceivable that Sketchup might also be used to incorporate the design into the base of the unit.

The shapes (in this case circles) on the design causes the light to be diverted.  However the students have the obvious, could they locate additional colours (such as lights that change colour randomly) or movement that would affect the display.

In the past we have had groups focussed on light, using shapes to distort the light and using this theme for their projects - including a group who used the 3D Printers to print brackets to hold multi-coloured lights that cycled colours in 2019.

In July of 2024 we looked at producing a small sized light house that was completely created using the 3D Printers you can read that post here.   

Laser Cut Senior Project: Desk Storage

Challenge: For a (senior) student to use the Industrial Laser Cutter to create a significant project following instructional videos.

Background: As we have noted before our senior students once a week complete a DPE Day, which is similar to a Technology program at some schools in New Zealand.    Typically in smaller schools the students sometimes travel to larger schools for external providers for this.   While this was something that was done in the past, our school several years ago made a decision to host this program ourselves.

What it means in practical sense for our senior students is that they complete in various subjects.   On of which focusses on the use of the industrial laser cutter that we have onsite.

This project shown here was completed by a Y8 student during a recent session with the laser cutting.   The student used Sketch-Up to design the different sections of the storage.  They followed a series of flipped instructional videos which provided the steps to create each of the pieces which had been created by one of our teachers (we could potentially make these videos available if there is interest).  

Once these pieces were designed they were then transferred to a USB drive before being laser cut.   The student then inserted the tabs into the correct location, applying wood glue to complete the process.   The storage was created in 5mm MDF with the exception of the handles of the draw at the bottom of the design which was 3mm MDF.  

The process was completed independently by the student and was able to have the final project checked off by the teacher.

Level of Difficulty: Hard.   This was not an independent task but was one that required a students abilities to use Sketch-Up and also follow specific instructions.   While it was very much following step by step instructions and this was very prescriptive it is nothing something that students without a laptop or skill in Sketch-up would be able to complete.

Timeframe: Each of the individual pieces took two minutes or so to complete.   However there are a number of them to make up the storage item, fourteen in total, however they could also be put into a single sheet of MDF and printed at one time.   The total time for the project including the gluing, the laser cutting, the design and the pieces drying was two and a half hours.

Size: The print measures 180mm across at the front and 130mm deep.  The print is 200mm high.   The draw is 40mm high.   

What we would do next/Next steps for our students: This task is a student following a series of instructional videos from a staff member, the next step would be for the student complete designs on their own with their own creativity completing the task as opposed to be following set instructions. 

The student will need to sandpaper the drawer to ensure that it is able to be opened and easily.

Laser Cut Storage Box - Senior Project

Challenge: For student to design a storage box, using the laser cutter.

Background: Our senior school students take part in what is called DPE once a week.  This allows them to focus on a particular subject including a focus on producing a project using the school laser cutter.

This storage box, shown left, was produced by a student in one day.    There were a series of instructional videos that were created by a teacher.   These had instructions for the students to follow, allowing them to complete the process independently but also allowing the student to introduce a degree of personalisation of the design, as some of the features could be modified without causing significant problem to the creation of the unit process.  This box is intended as an introductory task.   Followers of this blog will recognise that the boxes, which were also decorated  and sold as part of our school market day.

Once the process was completed (five minutes) the student was then required to take the individual pieces that made the box and glue them together with wood glue.   The wood used in this instance was 5mm MDF bamboo.   The box was then given time to set/dry and was complete within four hours of the project starting.

Level of Difficulty: Medium.   While this was completed independently it was completed by a senior student.  The senior students at our school are Y7/8 so twelve and thirteen.  This would be challenging for younger students, also of note that SketchUp was used so this requires a laptop.  

Timeframe: Five minutes for the laser cutting, while the entire project was four hours but this was related to the fact that the project needed to be glued, have the glue set and have the box complete.

Size: The dimensions of the box was 80mm across the front and all the rest of the sides.   The height was likewise 80mm as was the depth.

Next Steps for the student/What we would do differently: The obvious next follow up is to decorate the box by spray painting.  This project is designed as an introductory task, and the intention is to use this as a starting point, which will allow the students to apply the knowledge and think how they might create their own individualised boxes and projects.   As noted the time of the printing of the box parts is five minutes, which when compared to 3D Printing a box of this size which would be measured in hours.   The student will be working on a range of laser cut designs in the following weeks which will be detailed on this blog.

Laser Cut Chest - Senior Exemplar

 Challenge: To utilise the Laser Cutter for a senior student for a significant long term design.

Background: Our senior students at School have one day a week completing DPE (Design Production Education) also known as Technology at some schools which is typically one day a week.  At Auroa School we have supplied this to our senior students for nearly ten years now.  As part of the rotations our students have a laser cutter option.   This project based learning takes six weeks - although some students can complete the project in a slightly earlier time frame.   The six weeks when the work is being completed the students are able to focus on the project from 9am to 1pm in the afternoon.

The projects takes a number of stages.   At the core of the project is the students use of the laser cutter.   This is responsible for the shaping of the chest, as each of the slats needs to be cut from the template for the design.   There are various templates of similar chests that are available (freely) online via a simple search,

Once this has been located and the parts that form the base of the chest have been cut out the next step is to glue the chest together using a specific wood glue.    The box was left to dry overnight.

The next step is to work and construct the hinges.   The hinges at the rear of the box (see photo), the latch at the front of the chest while they are spray painted silver are also laser cut.

The wood is 5mm Bamboo MDF mix.   It is also possible to complete this process using different thickness of MDF and also different type of MDF.     The design was completed using Sketch Up.    The handles of the chest are also completed in a similar way. 

There are two layers of storage trays inside the chest.  The first layer, shown left in the photo contains three storage sections.  It has been lined on the inside with yellow felt.   The felt was sized up again using Sketch Up, and then cut on the laser cutter.    Yellow was chosen to complement the colour of the wood.

The wood glue used to construct the box was also used to place the lining and hold it in the correct place.    Holes were placed at the end of the draws and the holes had a insert to allow them to be lifted up.

The inside of the lid of the box was also lined with the same fabric felt.

The bottom layer of storage can be seen here.  With the first drawer removed the second storage consists of a draw divided into two long rectangles (for storage or pencils as shown).   The draw has been again lined with the same yellow felt that has been used for the other parts of the box.    The tray has been glued to the bottom of the box to hold it in place.

The internal hinges were purchased from a local hardware store.    

Level of Difficulty: Extreme.  This was a project that took a Y8 student who was twelve years old several weeks to complete.  It had a number of elements that needed to be completed to an extremely high level.   This design was not for the faint hearted and required skill, patience and detailing to make it complete.  This was a long term project for the student.

Size: 220mm long 130mm wide and 190mm high.  The storage inside reflects the dimensions of the inside of the box.

Timeframe: The laser cutting of the individual pieces including of the box, the handles, the sides, the detailing and the felt took approximately an hour to complete.  Given the dimensions of the box this is considered a minimum and does not include the time to construct the box, glue it, have the glue dry etc.  This was a project that took several weeks (working once a day) to complete, test and be happy with.

What we would do differently/next steps for students: Potentially the student could have 3D printed the handles (which are the part of project which are touched the most) or had a different choice with the felt for the lining however these are minor issues with this major project.  There could have been a different selection of wood for the outside