Light-Up Paper Star
A handmade laser-cut color-cycling light-up five-pointed paper star with spiral scrollwork.
Continue readingDragon Pop Up Card
Original origamic architecture / kirigami pop up card of a dragon’s head.
Continue readingViolet Box
New packaging/gift box design! This violet card stock has a wonderful velvety feel and, engraves to a beautiful contrast.
Vacuum Work Hold-Down Tray
Cutting paper in the laser can be challenging. The stock has to be held down uniformly across the surface, particularly if you are cutting small pieces out entirely. Otherwise, the air assist can move the cut-out bits around and, they can interfere with other cuts.
I mostly have been using Seklema hold-down mats for this. They have a sticky gel layer that holds the paper down without transferring any residue. They work really well but, they ablate with use and, are a bit expensive.
With some laser cutters, you can get a vacuum tray that holds lightweight materials like paper down with controlled airflow. There isn’t one of those for the Glowforge. So, I made my own.
This is heavily inspired by several other vacuum trays made by other Glowforge owners in this forum thread.
I designed this in Inkscape. I used a tabbed box generator for the two main bodies: the tray and the fan box. I modified the output to break the pieces into sizes I can cut in the Glowforge and, to add additional features like holes for the fan and electronics and channels for air flow.
The tray is 1/4” thick MDF. I lined the bottom with aluminum foil for extra protection in case any stray lasering gets through. It’s probably overkill but, I sealed the seams with silicone caulk to reduce air leaks. The cutting surface is a piece of perforated stainless steel plate sandwiched in an MDF frame. That is held down to the rest of the tray using magnets, with an EVA foam gasket to help with air leaks.
The fan box is 1/8” thick MDF with press-fit holes for the power connector and switch. The fan is bolted on to the end opposite the switch. This uses a 12v fan and a standard 12v power supply. The cord hangs out through the front of the lid of the machine.
I painted all the MDF black so it would look more finished and less cobbled together.
Cutting the plate steel without access to a shear was a new adventure for me but, worked out really well.
It works great, as you can see in the 1.6-minute demo video below.
Making of the Garden Lantern Electronic Pop Up Card
The Garden Lantern Electronic Pop Up Card I made in 2017 was one of the first big projects where I shot video documenting the build. There was a lot of footage and, I wasn’t very comfortable with editing videos at that point. The raw video just sat in a folder for a few years. I have done a bunch of build videos since then and, it occurred to me that I could probably manage to pull the old video clips together into a build narrative. I have been slowly putting that together in the last few weeks and, it is finally done!
As I noted in my original post about this project, this was inspired by and based on work done by Jie Qi and Natalie Freed. The Chibitronics Circuit Stickers project made everything a lot easier.
Spirals Bookmark Redesign
I designed a kirigami Spirals Bookmark last summer, mostly just taking what I did for one of my velvet embossing plates and, using that with minor changes. It was good but, there were a few spots where it was a little fragile – bits of connecting paper less than a millimeter wide.
More recently, I was inspired to redesign the spirals bookmark to make it a bit more robust. While I was at it, I made a few and, made a few of my Celtic key pattern design bookmarks and, put them all up in the new shop section. The designs are available individually, in three-packs and, in a variety pack with all three designs.
Snow Elf Manor Pop Up Card
A stately origamic architecture / kirigami pop up manor for snow elves, sent for the 2021 winter holidays.
Continue readingCeltic Spirals Bookmarks
This kirigami Celtic spirals bookmark is a variant of the pattern I used for embossing the purple velvet for the last dice bag. The gold and the smoke blue ribbon both look really good with the ice gold stock.
Hexagonal Box
This is a quick box I designed to package one of my little drawstring bags.
You can download the plain version below to make your own hexagonal box.
Hexagonal Box Pattern
This file is for personal, non-commercial use only. Note that, by referencing these, you are agreeing to release any variations you create under identical terms.
180-Degree-Open Pop Up Snowflakes
I played with several variations of this snowflake design back around 2002. There were a couple 180-degree-open card variants that I liked. They were both designed to be cut as four panels that folded together to produce a card with an integrated backing. I had some limited access to a laser cutter for a couple hours to produce the cards. I ended up going with the simpler of the two designs for the production run. That one was less sensitive to smoke deposition and, less fragile.
I always wanted to play with the other design a little more and, in 2020, I finally did a run of those on my own laser.
Smoke deposition was still a challenge, especially on a stock with a pearlescent finish and a little tooth. There is almost always some trade-off with that sort of thing and expedient production. I chose not to apply all of the full repertoire of techniques for these, opting to reduce wear and tear on expensive work-holding mats and, to make production faster.
I made a short production video featuring the jig-in-place technique, dry transfer adhesive and removing stray glue.