Abstract

The aim of this project was to investigate the limits and potential of the engraving function of the laser cutter, specifically on thin sheets of polyester. The research was conducted through a series of tests and try-outs that challenged the traditional use of the laser cutter. By experimenting with colours, types of polyester sheets, types of images and vector files, and the settings of power and speed of the engraving function the research progressively led to the development of the final technique. The technique uses transparent sheets of polyester that have been laser printed with a certain colour and engraves a vector file with gradients of black, greys and white. By increasing the power of the laser to the maximum that the polyester sheet can take without cutting through it, the heat will bend the material in certain areas, using what would be an unwanted side-effect as the main quality of the technique. With minimal intervention (taping it down at certain moments to avoid it moving) the machine takes the role of shaper of the polyester, creating unique pieces each time, thus transforming a function that is known for its precision and replicability into something that can create serial uniqueness. Additionally, the technique creates different textures into the material, resulting in areas of stronger or lower transparency that are highlighted best with a light source behind. Therefore, the final product is a wall decoration, but also an ambient night-lamp that turns on in the darkness. The product highlights the qualities of the final samples and uses the warping created by the laser to give the final shape of the lamp while also making the curves visible in the darkness.

Key experiments and insights

1. How do different images and settings transfer on the sheets of polyester through engraving?

2. How can colour be applied to the sheets and how does it interact with the engravings?

My approach for this project was to build on the observations of each part of the process and to try answering each question through multiple tests. I started by familiarising myself with the machine in its classical uses and increasingly intervening in ways that challenged the traditional use of the engraving function.

The technique uses transparent sheets of polyester that have been laser printed with a certain colour and engraves a vector file with gradients of black, greys and white. By increasing the power of the laser to the maximum that the polyester sheet can take without cutting through it, the heat will bend the material in certain areas, using what would be an unwanted side-effect as the main quality of the technique. With minimal intervention (taping it down at certain moments to avoid it moving) the machine takes the role of shaper of the polyester, creating unique pieces each time, thus transforming a function that is known for its precision and replicability into something that can create serial uniqueness.

More detailed reflection on each element

How can the laser cutter be used to shape/bend the polyester sheets?

How can the engraving function be used to create unique samples that defy the conventional use of the machine for its precision and replicability?

1. Using the engraving function on the laser cutter
2. Using thin polyester sheets
3. Using the heat of the laser-cutter as the main shaper of the material ->
Using the disadvantage of byproduct heat that can damage the material
as the core of the process
4. Challenging the machine’s precision by creating samples that turn out
slightly different every time
5. Using light effects to highlight the qualities of the material

Self-formulated Design Criteria

Using different markers/paints

Using laser/ink printers

3. How does the laser cut through the sheets?

Using the cutting function

Using the engraving function with high heat

Noticing that the material was bent where the black square was engraved

4. Seeing how the laser engraves different shades of grey and pure black

5. Experimenting with shapes, patterns and powers to try to bend the material

6. Trying to connect them with the heat of the laser

trying it on laminating sheets

Kind of worked on the laminating sheets, but not on the rest

7. Doing fulll-page gradients to warp the material

It worked better because i did not tape it to anything. (only as soon as it started bending I stoped it and taped some parts to prevent them from moving)

8. Seeing how colour affects the samples

Using markers to add colour

Using the laser printer

9. Noticing how different laser cutters offer different results

10. Brainstorming and making sketches to design the final product

(They also need different settings)

Two wall decorations that turn into night lamps when it is dark (thanks to the night sensors in the lights)

Reflection on Practice-based Research

This practice-based research allows the designer to discover the full potential of a technique through a hands-on approach that inspires new and unique interventions. Through my project I change the conventional use of laser-engraving, creating serial uniqueness through digital fabrication. This makes each of the samples special, as if they were hand-made. By hanging it on a wall, the night-lamp blurs the boundary between product and art. After these months of research it is clear to me that the technique can also have various other directions in which it could go if the research would be continued. Moreover, the use of light could be improved for the final product with the necessary extra time and funds, so as to better highlight the warping of the material.