SIH Level 12 - Laser Cutting

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STEM Innovators Book Level 12 Copyright © 2024 Author: Erin Goodwin Editors: Asma Mahamedi, Hari Mukul Sagar and Rebecca McDowell ISBN: 978-981-17736-1-7 Published by: SKOOL21 PTE. LTD. - Singapore DUO Tower, Level 8 #831 3 Fraser Street, 189352, Singapore All rights reserved, first edition 2024.

No part of this book may be reproduced, distributed, or transmitted in any form or by any means, including photocopying, recording, or other electronic or mechanical methods, without the prior written permission of the publisher, except in the case of brief quotations embodied in critical reviews and certain other non-commercial uses permitted by copyright law.

For permissions or inquiries, please contact: Email: info@skool21.org Website: https://skool21.org For the Ministry of Education approval only

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Preface Welcome to the Future of Learning!

Get ready to explore, build, and imagine like never before! The SKOOL21 STEM Innovators series takes you on an exciting adventure through science, technology, engineering, and math (STEM). Whether you’re just starting out or already a curious creator, these books are designed to help you think big, solve problems, and invent new ideas that could change the world.

Building on a Strong Foundation: From learning how simple machines work to designing with 3D models, each book builds on the one before it. You’ll travel through time—learning about cool inventions from the Industrial Revolution and creating your own along the way. No matter your grade, there’s something new and exciting to discover.

Learning by Doing: This isn’t just about reading or watching—this is about doing. Each book comes with a STEM kit full of tools and materials so you and your group can jump into hands-on challenges. You’ll build, test, explore, and learn by making things with your own two hands!

Real-World Impact:

Your ideas matter. Every project in this series connects to real problems people around the world are working to solve—like clean water, sustainable energy, and protecting nature. These challenges are based on the United Nations’ Sustainable Development Goals (SDGs), and your creations could help make the world a better place.

You’re Learning Like a Pro: The SKOOL21 STEM series is trusted by experts and based on international standards.

That means you’re learning the same problem-solving, teamwork, and design skills that real scientists and engineers use every day. You’re not just doing schoolwork— you’re getting ready to shape the future.

Embrace the spirit of innovation, ignite curiosity and empower the next generation of problem solvers with the SKOOL21 STEM Innovators series!

Happy Innovating!

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Introduction to the Kit The STEM Innovators Handbook Level 12 is designed for students who are ready to explore precision fabrication and digital craftsmanship through laser engraving and cutting. Building upon prior experience with 3D modeling and electronics, this level introduces learners to the world of advanced design-to-production workflows using the latest in desktop fabrication technology.

At the heart of this level is the Creality Falcon2 Pro 22W, a high-powered laser engraver and cutter built for both speedand accuracy. With its industrialgrade laser and intuitive design software compatibility, students can transform their digital vector drawings into precise engravings or cuts on a wide range of materials, from wood and acrylic to leather and metal.

Technical Features

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Table of Contents S. NO

STEM PROJECTS

SDG

PAGE NO.

I

THE LASER CUTTING KIT

06

II

ONSHAPE

09

III

PANEL WITH TABS

12

IV

PANEL WITH REVERSE TABS

15

V

CREATE AN ASSEMBLY

18

VI

LIGHTBURN

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1

AFFORDABLE HOUSING MODEL

24

2

PLANTER BOXES

33

3

STANDING DESK CONVERTER

42

4

CAR MODEL

50

5

INCLUSIVE STEM FIGURINE

58

6

RAINWATER COLLECTOR

66

7

WIND TURBINE AIRFOILS

74

8

BIKE RACKS

84

9

BRAILLE SIGN

92

10

REUSABLE SHIPPING CONTAINERS

100

11

AQUATIC CLEANUP HOOK

108

12

BEE NESTING HOUSE

116

13

BOOKENDS

125

14

MINI LOOM

134

15

LIVESTOCK FEEDER

142

C

CAPSTONE PROJECT

150123 05

Lesson 1: At the end of the lesson, the learners will: Identify and understand the components and safety requirements of the Creality Falcon 2 laser cutter.

Set up and use supporting tools like the smoke purifier and OnShape CAD software to prepare laser-cutting projects.

VOCABULARY

KIT CONTENTS

Laser Cutter

1/8" Bass Wood

Protective Cover

GETTING STARTED

LightBurn Key

In this lesson, we will learn how to set up and safely operate the Creality Falcon 2 laser cutter using a CAD file created in OnShape.

THE CREALITY FALCON 2 LASER CUTTER The Creality Falcon 2 is a desktop laser cutting machine that uses a 22W diode laser to cut or engrave materials such as wood, acrylic, or leather, based on designs created using CAD (Computer-Aided Design) files. The laser module moves along the X and Y axes, precisely following the path of your design.

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SAFETY GUIDELINES A laser cutting machine uses a high-density laser beam to engrave or cut materials by heating their surface until the material vaporizes. While this process avoids burning in many cases, most materials are inherently flammable and may catch fire if not handled properly. This can damage the machine and pose a risk to the surrounding environment.

Important Caution: Improper use of controls, settings, or procedures not specified in these instructions may result in hazardous laser radiation exposure. This product complies with IEC 60825-1:2014 safety standards and emits laser radiation classified above Class 1 through its laser aperture. Proper handling is essential for user safety.

Usage Guidelines and Safety Instructions: Location and Environment: Do not place this product near flammable and explosive materials, volatile solvents or heat sources. Please place this product in a ventilated, cool and dust-free environment.

Electrical Safety: Do not use power cords other than the one provided in the package during the installation.

Cleaning and Maintenance: Regularly clean the body and laser module with an anti-static brush and a dry cloth when the machine is powered off.

Operating Conditions: Please connect the silicone tube on the laser module whether using an air assist or not. This will reduce the risk of lens contamination.

Handling and Use: Operate between 5°C–35°C, avoid humidity and thunderstorms, and power off when not in use. Never touch internal parts or plug/unplug cables while powered on or during operation.

Material Support: Please place a flat object that the laser cannot penetrate under the processed material, such as aluminum alloy.

Eye Protection: During the laser engraving, please wear goggles to avoid vision damage caused by looking directly at the laser spot.

Ventilation: Smoke or smells may be produced during laser engraving and cutting. It is recommended to operate in a well-ventilated environment.

Child Safety: Children under the age of 10 are strictly prohibited from using this product without adult supervision to avoid injury.

Supervision: Never leave the laser cutter unattended while it is running.

Fire Safety: Prepare fire extinguishers as a backup. Regularly maintain and inspect the fire extinguishers.

Legal and Ethical Use: Users must follow all applicable laws and regulations when using this equipment. The machine must not be used for any illegal or unethical purposes. We will not be responsible for any consequences resulting from misuse or violations.

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ASSEMBLY & POWER SUPPLY For more assembly and care instructions, please see the wiki: https://wiki.creality.com/en/laser-engraver/falcon2/user-manual.

It will need to be plugged into a 240V outlet, common in garages or workspaces. If your workspace only has 110V outlet, you may need to rewire the outlet or purchase a step-up converter.

SMOKE PURIFIER The Smoke purifier helps catch the particles that are burned off of the material.

It should always be on when the machine is being used to maintain good air quality. It can be plugged into a standard 110 V outlet.

ONSHAPE onShape is the 3D modeling software that will allow us to model our laser cutting designs and create a STL or 3D modeling file. First, create a free education account at the following URL: https://www.onshape.com/en/education/sign-up. Once you have created an account, you will need to verify your email address to be able to login.

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AFFORDABLE HOUSING MODEL End poverty in all its forms everywhere.

OBJECTIVES At the end of this activity the learner will be able to demonstrate an understanding of the following:

Next Generation Science Standards Engineering Design HS-ETS1-3 Evaluate a solution to a complex realworld problem based on prioritized criteria and trade-offs that account for a range of constraints, including cost, safety, reliability, and aesthetics as well as possible social, cultural, and environmental impacts.

Cambridge Science Physics: Physical Quantities and Measurement Techniques 1.1-1 Describe the use of rulers and measuring cylinders to find a length or a volume.

ISTE 1.4 Innovative Designer Students use a variety of technologies within a design process to identify and solve problems by creating new, useful or imaginative solutions.

Engineering Connection Design and laser cut flat house pieces whose sides will fit together with joinery to create a three-dimensional model.

Common Core Mathematics

STEM Careers Connection

Building Functions

This project includes tasks that reflect the work of professionals in the following careers:

HSF.BF.B.3 Identify the effect on the graph of replacing f(x) by f(x) + k, k f(x), f(kx), and f(x + k) for specific values of k (both positive and negative).

Architect

Cambridge Mathematics Urban planner

Transformations C7.1.3 Recognize, describe and draw the following transformations: Enlargement of a shape from a center by a scale factor.

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Project 1 : INTRODUCTION Affordable housing is a global challenge, with many communities needing costeffective solutions. Using Onshape, a free Computer-Aided Design (CAD) software, we can design efficient, space-saving housing models that reduce material waste and construction costs.

Your team will design a prototype, then laser cut and assemble a scaled model using joinery techniques for a hands-on 3D visualization.

The Global Housing Crisis & Poverty

Approximately 1.6 billion people live in substandard housing globally.

(Source: International Finance Corporation)

Affordable Housing

Design efficient, space-saving homes and use math concepts for precision

Innovate with Precision

Laser cutting allows for fast, repeatable production of precise housing components.

Material waste is minimized through efficient design and cutting techniques.

The modular, scalable models make it easy to replicate solutions for different communities.

93% of adults don’t have access to housing finance.

(Source: World Bank Global Findex, 2017)

This hands-on process uses geometry to apply transformations and scaling, and engineering principles to ensure structural integrity.

DEFINE THE PROBLEM A suburb has been tasked with adding 1,000 more affordable housing units for refugees. They have asked your design firm to design an affordable housing model that will fit together with joinery so that it can be approved by the board before construction commences. Can your team design an affordable housing model to help the firm?

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Your affordable housing model is more than a classroom exercise— it’s a prototype for real-world impact. Through STEM innovation, you’re helping design pathways out of poverty.

MEASURE YOUR SUCCESS Your affordable housing model should: 1. Have four sides that fit together with joinery 2. Feature windows and a door

Your affordable housing model must: 1. Fit on the 400 x 415 mm cutting area 2. Use only your laser cut materials

TEAM ROLES Lead Modeler Fabrication Specialist Recorder and Reporter Testing Supervisor

MATERIALS

Details

Laser Cutter

1/8" Bass Wood

Smoke Purifier

REQUIREMENTS Requirements Before You Begin This Project 1) Have you created a student onShape account? a) https://www.onshape.com/en/education/sign-up b) Use School Name: Skool21 c) Validate your email address. d) Check that your browser is compatible.

2) Do you have a mouse?

If you have answered yes to all of the questions, you are ready to begin this project.

If you have answered no to any questions, you might want to review that section before you begin this project.

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VOCABULARY

Joinery CAD Fabricate

The method of connecting pieces of wood together with tab-and-slot joints An acronym for Computer-Aided Design; used to create design of real-world objects To laser cut wood into pieces that can be assembled into an object

GETTING STARTED Step 1. Log in to your onShape account.

Step 2. Click Create -> Document.

Step 3. Name the file “Project 1: Affordable Housing Model.”

BUILD THE MODEL Step 4. Create a new sketch and use a combination of the rectangle tool, line tool, trim tool, and dimension tool to create a side of the front of the house. The goal is to create rectangular house profiles that snap together as shown below.

Step 5. Copy and paste the house side to create the outline of the opposite side.

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Step 6. Extrude the sides to give them 0.1 inches of thickness.

Step 7. Create another sketch to create the windows and doors.

Step 8. Extrude the windows and doors, but select “Remove” in order to subtract rather than add the material.

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Step 9. Inspect your design from multiple angles to ensure it has come out the way you intended.

CHALLENGE Can you design the second set of walls that has joinery to fit with the first two?

DESIGN AND PLAN Create a sketch for your wall design. Note that you will want the tabs to fit with the existing tabs on the first two sides. The following image shows an example solution, but you should come up with your own!

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TEST Go back to Measure Your Success and check the boxes. Does your project meet all the criteria and constraints?

SHARE AND IMPROVE Take turns presenting solutions with a partner. As you listen to your partner, consider which parts of their project effectively meet the goals. Offer constructive feedback on areas where they could improve. Record the feedback you receive.

Partner Feedback Design Strengths

Suggested Improvements

MATH AND SCIENCE CONNECTION 1. House permits were granted, but last minute scaling was necessary due to zoning laws. The general contractor knows that the plans will need to be resubmitted if the pitch of the roof has changed. a. If the house panels were horizontally scaled by a factor of 1.2 and vertically scaled by factor of 1.5, will the roof pitch change?

b. If the house is shifted 1.2 km south instead of scaled, will the roof pitch change?

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c. Which of the following function transformations represents a horizontal scale, and which represents a vertical shift? i. y = f(x) + a ii. y = f(x + a) iii. y = af(x) iv. y = f(ax)

REFLECT End poverty in all its forms everywhere.

1. How could the affordable housing model help meet the SDG Goal of No Poverty?

2. How might people in the career fields listed for this project also help contribute to the SDG Goal of No Poverty?

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3. Self-reflect on your work on this project.

I can identify key parts of a problem to solve it effectively.

I can model the prototype in onShape.

I can adapt my model to meet the challenge requirements.

Try to model and print the solution yourself. If you are having trouble, look at the images below for guidance.

SAMPLE SOLUTION Assemble the pieces in “Assembly 1” to ensure they fit together before laser cutting. Use the rotation and translation tools that pop up when you select the sides to move them into position such that the tabs mesh. Be patient the first time you try: it is hard to learn to move the sides on the correct axes at first.

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