Metal Burr Puzzle
After creating a 3D surface assembly, it is necessary to convert the surfaces to 2D curves for the machine to generate cutting g-code. This process is illustrated in an example Rhinoceros file available to all students. Going from 3D to 2D uses the 'unrollsrf' command. Subsequent steps are used to format and align the curves for faster/efficient cutting.
Part of being a technician at the AACE lab involved writing instructions and making example projects to showcase the functionality of different equipment in the lab. This metal burr puzzle was used to display how to prepare files and use the Fablight metal cutter to cut cylindrical tubes. This type of project was made because it involved an assembly of different shaped pieces that did not require any welding to complete, allowing it to be completely made using only the AACE lab and accessible tools.
Once each piece was cut, the edges were deburred and the puzzle was assembled according to the video on the left. The design of the larger 13-piece puzzle was modified from the original design by Two Brass Monkeys to allow for use with hollow tubes instead of solid cylinders, which cannot be cut with the laser cutter for large diameters. The smaller 6-piece puzzle was made to be more easily assembled to show the individual pieces and how the cuts were made.
