Before #2: My front door, in need of paint, some aesthetic happiness, a fixed doorhandle, and summer. My desire to add a little decoration to the door is, in part, what led me to the Makerspace. I had an idea for panels to go on either side of the door, but no equipment for making what was in my head. When I saw that the Makerspace had cnc routers…

IN THE MIDDLE

I took photos of leaves from the oak tree in our yard:

I traced the leaves in Illustrator, and — by looking at the structure of the tree — made my initial design. I exported the file into svg (with hints from Shane), and Ed helped me use Cambam to convert the svg file into the gcode that the Mogul desires.

After generating the gcode, we cut the first panel. For me, watching the cutting was like Christmas: exciting — while for Ed, stepping me through the process, this must have been like a long slooooooooow Christmas, watching the design appear through the three passes the router bit made to cut each (complicated) path. (In truth, Ed’s patience and help were the real Christmas present for me.)

This panel was an experiment for me, to learn about how thin and delicate the connecting pieces could be in such cutting. And I learned: what you cannot see in the picture above is how two of the leaves broke off quickly.

In the next Illustrator file I made (which I then cut on the Mogul with Steve Pilon’s also very generous and patient help), the leaves overlap and made their stems thicker. You might be able to see this in the final picture below, which shows the panels painted and mounted. Merry Christmas!

THE END

We know you’re wondering what Mike B. has made recently. Well, he made this chair. And he liked it so much he made another one. Now he’s got two chairs like this sitting on his front porch.

What did you make this week?

Then, the laser cutter…..

Using the adobe suite of products I created two black and white drawings to be translated to wood blocks.

Unlike traditional transfer/carving methods, I decided to utilize the 60W laser to etch the images into poplar wood vs. carving.  I chose poplar for its hardness and ability not to warp as easy as pine or other softer woods.  60W laser setting was 100 power, 60%speed, 500 PPI

The image below is a 5″x7″ laser cut of the black plate of the rooster image.

Top-Left is the black plate for the left facing rooster.  Bottom-left is the red plate for the left facing, top-right – red plate, bottom right – black plate

The following image shows the red left-facing plate printed, and the black plate inked up and ready to be printed

The first red/black rooster print, along side the right facing black print.

And of course, if you do one, you have to do many.

My youngest son and nephews pre-school is tiny. Literally it’s two classrooms, but it’s a great environment for them both which includes identical playsets in each class.

Hundreds if not thousands of kids have played on them. Being built in the 80’s when building codes weren’t as strict, they were no longer compliant.

While the wood is still good, had been sanded well and sealed well there were a few problems.  The banister rails been deemed to be too short and the handrails needed to have another one put on the bottom under the other two on either side.

The choices were to surround the play sets with a 6 foot giant landing mat around the sides, or to raise the banister rails and add another handrail. A landing pad would have taken up far too much room in the class so I volunteered to rebuild some of the rails so they met code.

Because construction was going to take a little while (actually it turned out to be a long while, started before Christmas it was finished in early April), the rail cutting / routing / sanding was going to take place off site and then assembled onsite during a weekend afternoon

First thing was to take lots of pictures, and lots of measurements.

I did up some high-level sketches just showing how the rails would be raised.

The next step was to cut up a whole pile of 2”x2” rails to the desired height with a 45 angel cut on the ends to match what was originally there. The rails also had been rounded off with a quarter round router bit, so I did that as well.

I knew there was no way I could match the old finish that was on the original wood so I decided to go with something a bit brighter and engaging for the kids mixing blue, red, green and white paints that I had my son pick out. Then it was just a matter of cutting and routing. Here are some shots of the wood after cutting but being painted. The coats ranged from 4-5 to get a deep coverage and then 3 coats of a clear poly to brighten it up.

By some miracle the measurements all turned out perfect, which is nearly a first for me. We still have the bottom hand rail to make but that will be easy to do.

I used the laser cutter to make a Raspberry Pi case, and rather than leave the front of it all boring, I added an 88nine Radio Milwaukee logo to it. (Since I had a project that involves a Raspberry Pi and 88nine, it seemed appropriate.)

I started with the original 88nine logo, which is brown and orange. I couldn’t find a nice hires version, but a quick web search turned up something that would work…

To start with, I converted the logo to black and white, since color wasn’t going to matter to the laser cutter…

I then separated the top bars (which are orange in the original logo) and dithered them to create a visual separation from the bottom part of the logo that was brown in the original.

Here’s a close-up of the dithering pattern. It’s extremely simple, but it worked. I’ve done a lot of work with halftones and dithering, and you can get extremely complex, but sometimes the simple things just work.

Here’s a close-up of the final piece of Baltic Birch plywood with the logo etched in it. I’m pretty happy with how it turned out.

If you saw Shane’s post Submission for the 100 Square Feet of Art Charity Event you probably wondered if anyone else managed to create a piece of art for the event, and if they too used the laser cutter. The answer to both questions is “Yes!” and here are the two pieces I created, M1 and M2.

There’s an in-depth (and potentially boring) post about these pieces over on my blog titled Two Square Feet of Art. Enjoy!

This is my newest piece, cut and etched on our 60 watt laser cutter.  Both images are from pictures that I took out at a couple of graveyards.  I inverted the image in the background so that the sky was nice and dark and the trees were bright.  Unfortunately, this washed out a lot of the tombstones in front, so I’m going to try re-etching this piece before I offer it up for sale.

The back piece took approximately 1 hour, 20 minutes to etch as a 11.5″ square.  Additionally, I found that the margins are a bit off on the cutter.  The left margin has shifted around 1/8″-1/4″  to the right, so the piece wasn’t perfectly centered.

In the wee hours on Black Friday, we got the materials: 4 sheets of wood, 4 boxes of 100 count LED lights, and extension cords. After sketching out the design…

…and cutting out the letters…

…it was time to drill the 400 holes and hot glue all the lights in place.

It only took a weekend to make and hang these and I think the end result is well worth it.

Art for charity’s sake

When Raster mentioned the event, “Red, White, & Black: 100 Square Feet of Art“, I thought I’d take part.  The general idea is for artists to pick up a 12×12” piece of wood and “art” it somehow, transforming it into a mini-masterpiece for an auction to support pets in need.  The auction takes place on December 7th, so be sure to stop in.  They’re featuring live music and food along with a raffle and the auction.

Taking a cue from some Art Boxes I’d been working on, I decided to use a similar vine motif with an orchid etched in the center.  After studying it for a while, I thought it needed depth, so I laser etched a photograph that I took out at Boerner Botanical Gardens for the backdrop.

Still not content, I wanted the darker shadows of the vines to play along with the lighter picture behind, so I cut several half-inch blocks to raise the top piece above the back piece.

The back has been treated with teak oil while the front was stained with Bombay mahogany satin stain.  The blocks are put specifically in each corner in order to maximize the amount of light that hits the back piece.  I may add a few extra spacers for support in the coming days.