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Week 2: 2D Design and Cutting

As a kid, and even more recently, I've always loved creating 2D shapes and art with xacto knife cutouts. I enjoyed bringing 2D cutting into 3 dimensions this week immensly.

Hand-Cut Sheep

Using Nathan's polar pattern method, I started by making a circle with 6 cut-outs in order to test my kerf value.

Fusion 360

Initially, the two circles didn't hold together firmly, instead slowly sliding apart. After talking with Nathan, I thought that I might have incorecctly measured the thickness of the cardboard; only measuring the most uncompressed cardboard dimension.

Falling Circles

However, when I went home over the weekend for my bandmate's wedding, I brought the two peices with me. When I showed them to my father, and they, seeminly magically, fit together perfectly. My assumption is the high humidity in DC let the cardboard expand slightly.

Sticking Circles

For my big finish, I wanted to create a set of Dungeons and Dragons dice made as a cardboard kit. I decided to start with a D4. While I hope to eventually be able to engrave a decorative number on each side, I started by cutting simple numbers out of each side.

Dice Parts

My first design had two problems. One, I foolishly put 1 number on each side, not the three numbers required. Secondly, I didn't take into acount that the ciruclar connectors were not angled. The only other time I've used this slotting method was with wood, using a chop saw which could be angled. Because the cardboard is fleixble, I was still able to assemble the die

Constructed Dice

Next step: adding the other dice and engraving numbers!