Fab-in-a-Box Invention Kits: Exploration

Set the tone for creativity by having a whimsical cardboard critter actively cutting on the laser cutter as learners enter. Display a few finished critters around the room to showcase variety and inspire ideas. This setup encourages learners to imagine what their own critters might look like. Load the step-by-step xDesign template on each student’s computer, and have the tutorial video or photo guide queued up. Prepare cardboard sheets and optional materials, like pipe cleaners and brads, at a central supply station. Make sure the laser cutter is prepped and safety procedures are posted clearly.

Welcome:

Welcome learners, and introduce the activity: designing a cardboard critter using a step-by-step xDesign template. Let learners know they’ll be building on their previous skills by creating custom shapes, adding parametric slots, and using alignment tools to bring their designs to life. Reinforce the role of CAD software in enabling precise, repeatable design work. Explain that this session focuses on creativity and iteration, learners will design, cut, and test their critters, then refine them based on performance and feedback. Show a few critter examples and highlight the one currently being cut to inspire ideas and encourage learners to think about what makes a design expressive or functional.

Context:

Rapid prototyping, press-fit slot-and-tab assemblies, parametric design:

In the real world, engineers and inventors often face tight deadlines for solving problems. It’s easy to get overwhelmed or to not know where to start! Invention kits can help facilitate brainstorming and accelerate the prototyping process. They provide a ready-made set of components that can be easily assembled and reconfigured to test out various design concepts.

LEGO bricks are a great example of an invention kit. They can be quickly assembled or disassembled in a variety of ways to illustrate a concept or test out an idea. Your invention kits will work similarly, allowing you to build upward but you get to customize the pieces!

Key terms:

Parametric Design: This design process uses parameters to define a model’s geometry. By adjusting these parameters, designers can easily modify and optimize their designs. This approach is particularly useful for creating customizable and scalable components in CAD software.

Kerf: This is the width of material removed by the laser cutter during the cutting process. Understanding kerf is crucial for ensuring that parts fit together correctly, as it affects the precision of the cuts and the final dimensions of the pieces.

Toolpath: This is the path that the laser cutter follows to cut or engrave the material. The toolpath is generated from the CAD design and dictates the movement of the laser, ensuring that the design is accurately

transferred to the material.

Brainstorming ideas for your cardboard critter:

Think about what kinds of parts it might need—both decorative and functional.

Here are a few ideas to help you get started:

Body parts: heads, arms, legs, tails

Decorative: wings, flowers, hats, mustaches

Mechanical: wheels, gears

Structural: triangles, rectangles, bars

Sketch a few of your ideas on paper to help visualize your critter. Then, open the step-by-step

xDesign template on your computer.

Follow the guided steps to:

Create custom shapes

Add parametric slots

Use tools like patterning, alignment, and centering to make sure your parts fit together

As you design, think about how your critter will move, balance, or connect. You’re using CAD software to bring your ideas to life with precision and creativity.

Decide on slot placement:

Looking at your designs, decide where you want to add slots or holes. Remember, this is how your pieces will fit together, but only add a few per piece! Too many and your material’s strength will suffer.

Add lines or narrow rectangles to your design sketch to indicate slot placement.

Open the step-by-step xDesign template:

Follow the guided template to begin building your critter. Use the tools to create custom shapes and add parametric slots. Try using patterning and alignment features to keep your design organized and symmetrical.

Plan slot placement carefully:

Decide where your critter parts will connect. Add slots to key areas, but avoid overcrowding; too many slots can weaken the cardboard. Use narrow rectangles or lines in your sketch to mark slot locations.

Preview and refine your design:

Check your design in xDesign, and make adjustments as needed. Think about how the parts will move or balance once assembled. Save your file, and prepare it for laser cutting.

For xDesign Steps Click Here

xDesign steps can also be found:

In xDesign under Content

Laser cut the designed parts from cardboard sheets:

If using xDesign:

Click “fab connect.”

Open laser cutter lid, and place stock material onto honeycomb.

Click process.

If using XCS:

Import design file: Save your CAD file in SVG or DXF format. Then, import it into XCS. As long as it was created at a scale that can fit on the laser bed, it will open at actual size. You can double check by selecting the design and looking at the dimensions shown in the “size” boxes across the top of the screen.

Configure cut settings: Select the appropriate material from the menu on the right side of the screen. (Hint: “corrugated paper” = cardboard.)

Choose cut settings: Select all elements you want to cut and choose “cut” under “processing type” in the object setting menu on the right.

Optional: engraving – If there are any decorative elements you wish to engrave instead of cut, select them and choose “engrave” under “processing type” from the object setting menu on the right. They should fill in. Enter the appropriate settings for your chosen material.

Prepare laser cutter:

• Open laser cutter lid and place stock (balsa) onto honeycomb.
• Manually drag laser head over center of stock.
• Close lid.
• Click “auto focus,” and wait for machine to focus.
• Open lid. Manually drag laser head to top left corner of desired cutting area.
• To check framing, click “framing” in XCS, and then press the button on the machine. The laser head will frame the area to be cut. If it does not fit on the stock or overlaps a previous cut, adjust the starting position as needed.

Run job:

Click “process” in XCS, followed by the button on the machine.

Remove pieces:

Check to make sure all pieces cut through, and rerun if not (adjusting settings as necessary).

Remove workpieces and scrap stock from machine bed.

Close lid.

After the cutting is complete, carefully remove the shapes from the cutting bed. Clean off any debris or residue from the edges of the shapes.

Consider saving your excess material once you’ve punched everything out; this can be incorporated into your designs, too!

Now for the fun part: Build!

Use your construction kit to build something new! Make assemblies by slotting the shapes together to form three-dimensional structures. Experiment with different combinations of shapes to build various structures. Take note of any improvements or modifications that could enhance the kit’s usability, and consider iterating your designs accordingly.

Congratulations! You’ve successfully created your very own invention kit. Whether you’re using it for brainstorming, rapid prototyping, or unleashing your creativity, your kit is a versatile tool that empowers you to bring your ideas to life. Keep exploring and experimenting with your kit to unlock new possibilities and innovations!

Extensions:

3D print connectors

Incorporate flexures

Design and categorize multiple types of pieces:

Anatomical = heads, arms, legs, hands, feet, tails

Whimsical/decorative = wings, horns, accessories

Mechanical = wheels, gears

Structural = beams

Pose prompts to overcome “blank page syndrome” and encourage creative thinking. Ask learners to build a character, building, or prop and write a story that incorporates it (English), re-create a favorite landmark or design a new monument (civics/history), or design something with multiple degrees of symmetry (math/geometry).

Discussion Questions:

What features made their critter unique or expressive?

What challenges did they face during assembly?

What would they improve or add in a second version?

Optional Tie-ins:

Mathematics:

Geometry and Measurement: Integrate lessons on geometric shapes, angles, and measurements. Students can apply these concepts when designing their invention kits, ensuring accurate dimensions and fit for the slot-together pieces.

Algebra and Parametric Design: Use algebraic expressions to define parameters in CAD software. This helps students understand how changing variables can affect the overall design, making it easier to create scalable and customizable components.

Art and Design:

Graphic Design: Introduce basic graphic design principles, such as balance, contrast, and color theory. Learners can apply these principles to create visually appealing and functional invention kits.

Creative Expression: Encourage learners to express their creativity through their designs. They can incorporate personal themes, stories, or messages into their invention kits, making each project unique and meaningful.

Engineering and Technology:

Mechanical Engineering: Explore the engineering behind slot-together mechanisms. Discuss how different types of joints and connections can create stable and functional three-dimensional structures.

Technology Integration: Highlight the role of technology in modern design and manufacturing. Discuss how CAD software and laser cutters are used in various industries, from product design to architecture, and how these tools can streamline the prototyping process.

Career Connections:

Learning to design and fabricate invention kits using CAD software and a laser cutter opens up a variety of exciting career paths:

Mechanical Engineer: Mechanical engineers use CAD software to design and analyze mechanical systems. The skills learned in creating invention kits can be applied to prototyping and developing functional components, enhancing the ability to design efficient and innovative solutions.

Graphic Designer: Graphic designers can use CAD software to create precise and intricate designs. The experience of designing invention kits helps in understanding the principles of form and function, which are essential for creating visually appealing and effective designs.

Physicist: Physicists often need to create experimental setups and prototypes. Knowledge of CAD software and laser cutting can aid in designing and fabricating custom components for experiments, allowing for precise control and customization of experimental apparatus.

Marketer: In marketing, the ability to design and produce custom invention kits can be a valuable skill for creating engaging promotional materials and interactive products. These kits can be used to demonstrate product features, engage customers, and enhance brand experiences.

These career connections highlight the versatility and applicability of the skills learned in this lesson, showing how they can be valuable in various professional fields.