Part A: Model a Thing (then 3D print and laser cut it)
Well, I have officially progressed from pretending to be useful to completely admitting my uselessness. Hurrah. In the last lab, I modeled a cute little star table, which could, with a little imagination, be considered functional. This lab, I modeled a mushroom. It actually turned out alright. Below is an image of my sketches, the Rhino model, and the 3D printed model.
While it is “alright,” it is not, in any sense of the word, functional. What on earth can you do with a mushroom model? You can cut it out of slices of cardboard to make a larger useless mushroom! Cool!
But honestly, working with the laser cutter is very fun. I thought I was proud when I held my little tiny star table in my hands, but that was nothing compared to the joy of the laser cutter. The mushroom laser cut is honestly a fairly substantial disappointment, but the joints (I’ll get to those later) are amazing.
The mushroom didn’t turn out very well in part because I made a mistake while cutting my sheet of cardboard, so when we uploaded the Rhino file into the laser cutter, it was just a bit too big. Hence, my cardboard mushroom doesn’t have a well rounded bottom, but I am not overly bothered by that. What annoys me a little more is that, for some reason, the cap of the mushroom is not round. I don’t know exactly what happened between the Rhino model and the laser cutter, but my mushroom ended up considerably flatter than I imagined. My hypothesis is that I either a) lost pieces or b) entered the thickness of my material incorrectly. Because I don’t actually think a or b are true, there is also option c) the mushroom just doesn’t translate well to slicing and laser cutting.
The Rhino model was constructed by revolving one curve for the stem and a second curve for the cap. I used a cage edit on the cap to get some more organic fluctuations and waves. Then, I added the little shelf by projecting a curve onto the stem of the mushroom and lofting it into another curve. Finally, I did a lot of splitting and BooleanUnion-ing to get a single closed object. Nifty.
To do the laser cutting, I used Fusion360’s Slicer app with vertical slices. Initially, I tried waffling (or slicing in both the x and z direction), but it didn’t play well with my model.
Part B: Model some more things (that go with the first thing)
And now I begin realizing that modeling a mushroom may have been a mistake… What goes with a mushroom? Like a tree? I am NOT modeling a tree. No way. So the mushroom was reborn as a… lamp. Naturally. I needed to model a base for it anyway (funny thing about irregularly rounded bottoms is that they don’t tend to stand up. Whoops), so I just used my imagination. I think that if I ran a wire through the base and hooked it up to a light bulb in the cap, this mushroom would provide illumination. To turn it off, you would just pull it out of the base. And then lay it on the floor or something. I don’t know; that is someone else’s problem. To add to my mushroom-lamp environment, I modeled a mushroom-cap chair, leaf candle holder, and leaf footstool. The general premise is melding organic and non-organic shapes to make furniture. This is what I ended up with:
Part C: Wood Joinery (AKA my long-lost love)
Once upon a time, long ago, my family did stuff with wood. I know this because we have a wood cabin some great-great-uncle built, a bunch of handmade wooden chairs, and a super cute little desk that my grandfather made and painted for me (I think). All of this is to say that I believe I have wood joinery in my blood.
Just kidding. I’m just less bad at it than the rest of this. I have a natural eye for what is going to stick together and what is going to fall apart, which is very handy in making joints. This bit was also interesting because it seems more functional than my mushroom-lamp. This is an illusion—there is nothing more useful about my wood bits than my cardboard bits, but it makes me feel better. Also, I love working in wood. It smells nice, looks nice, and has an overall cleaner feel. All of this is to say that I did some joinery, and I liked it a lot. Here is what I ended up with:

How did I get those nice looking wooden puzzle things? Rhino. Conveniently, the laser cutter is about a perfect width for things to just fit together, so I didn’t give my model lines width, and it took care of it for me. I modeled three joints: a 90 degree joint called a “Tenon with Star Mortise,” a simple, flat, star joint, and my personal favorite, a four-way key joint.
I’ll begin with the Tenon: First, I made a rectangle. Then I made another rectangle. Wow. High tech. I liked the look of the rounded edges on the key (which is actually a CMC machine issue and can be fixed with the laser cutter), so I made two circles and connected them with curves. This required a lot of splitting and joining (more than I anticipated), but it turned out alright. Then, I bought my material (1/4 inch red wood pine because the Lowe’s in Dillon didn’t seem to have any baltic birch or staff members I could ask about baltic birch). I measured the width of the wood and made a rectangle on my rectangle that was the same width of the wood and length as the key attached to the first rectangle. Easy.

Next, I will talk about the flat, star-locking joint. I created this joint after looking at this 50 Digital Joints poster. It was also pretty simple. I made two rectangles and put a six pointed star in each. Then I connected the stars with lines, split and joined, and had a star shaped key. I duplicated this and moved it down (to add strength to the joint), so I had two double-star keys. Ta da!

And last by not least, the four-way key joint. This is by far my favorite and also the least useful. Are you picking up on a theme? I tend to be drawn to useless but aesthetically pleasing things. This joint was perhaps the most difficult to make, though still not hard by any stretch of the imagination. I made a long, thin rectangle, then duplicated it three more times, rotating 90 degrees each time. Then, I made the top of the key out of curves, lines, and a small rectangle. I duplicated the key and rotated it three times as well, before connecting it with lines. After joining the center key into a single piece, I made lines from the corners of the four rectangles to the key, then split the rectangles on the lines, and joined them to the diagonal lines. In order to get the whole shape to fit on my cardboard, I needed to rearrange one of the arms, so I duplicated a single arm of the key and joined it to the rectangle part of the arm, making it a cut out. The shape printed well, but if I were to do it again, I would make a single arm and key cut out, then duplicate and rotate that whole thing three times. After I printed this time, I tried rearranging the arms, and they don’t fit well onto other keys, meaning that somehow, the key is not perfectly symmetrical. This really doesn’t bother me that much, but in the future it may be a good thing to keep in mind (and also make the process much faster).

Overall, this lab was a lot of fun, and I am very, very eager to work more with the laser cutter. You can do so many interesting things. On my list is:
- Make myself a wallet out of bendable wood
- Make a joint out of the tatoo design for my sister
- Make joints that actually work and consider trying to model something useful (wow, crazy)
But all those things are outside of the scope of this lab, so I’ll sign off for now!