Aluminum Custom Coasters

Coasters are such a fun and easy project! Using a water jet cutter and laser cutter, I was able to create custom engraved coasters for my roommates and I to enjoy. I appreciated the sleek design of anodized aluminum and wanted to create something of my own that was unique and personal.

1. Sheet of anodized aluminum
2. Water jet cutter
3. Garnet abrasive
4. Glowforge laser cutter

I used Canva to design six different options! Two resemble glasses, two include the names of my roommates and I, and the final two represent images of our school. After conducting user interviews, I decided on the circular "P2" design and the bricks as they were personal to our group and our school.

In Canva, I found an image of scalloped circles and edited the coloring so they resembled an aluminum color. I then added text, images, and/or shapes to create my designs. I saved my image as an SVG file for further use.

Finally, I uploaded the image onto Adobe Illustrator to turn the raster into into vectors for use with the water jet cutter.

Define the Cut Paths

1. Outline the Shape: Ensure all lines in your design represent where the water jet should cut.

Scale the Design

1. Measure the Material: Adjust the design size to match the material’s dimensions and thickness.
2. Account for Kerf: The water jet removes a small amount of material (kerf). Factor this into your design for precision.

Add Tabs (if needed)

1. If you're cutting small parts, add tabs to hold the parts in place during cutting. These are small uncut areas to prevent the piece from moving.

Test the File

1. Preview the Tool Path: Use water jet software to preview the cutting paths.
2. Run a Simulation: Many water jet systems allow simulations to detect errors in the file.

Transfer the File to the Water Jet Cutter

1. Load the file into the machine’s software (e.g., FlowPath, OMAX IntelliMAX, or others).
2. Configure machine settings like speed, pressure, and abrasive flow based on the material.

Prepare the Material

1. Secure the Aluminum: Clamp the anodized aluminum sheet or part to ensure it doesn't shift during cutting.

Set Parameters

1. Pressure Settings: Adjust the water pressure to about 50,000-60,000 PSI for cutting aluminum efficiently.
2. Abrasive Flow Rate: Set the flow rate between 0.5 to 1.0 pounds per minute, depending on the thickness.
3. Cutting Speed: Adjust speed based on the aluminum's thickness. Slower speeds improve precision for thicker materials or complex designs.

Cutting Process

1. Perform a Test Cut: Start with a small test cut to ensure the settings are correct.
2. Monitor the Process: Watch for issues like nozzle clogging or uneven cuts.
3. Cooling: The water jet naturally cools the material, preventing heat damage to the anodized coating.

Post-Cutting Cleanup

1. Rinse the Part: Remove any abrasive particles and debris.
2. Inspect Edges: Check for burrs; if present, deburr lightly with a fine file or sandpaper.
3. Preserve Anodized Coating: Handle with care to avoid scratching the anodized surface.

Prepare Your Design

1. Use design software like Adobe Illustrator, Inkscape, or Glowforge's built-in software (you can easily transfer your design from Canva or another software).
2. Set to Engrave: Create your design as a vector or raster image. If it's text or a logo, ensure high contrast for clarity.

Choose the Right Settings

1. Power: Use 100% power.
2. Speed: Start with a moderate speed (e.g., 1000-1500 DPI) and adjust based on test results.
3. Line Density: For detailed engravings, set a high lines-per-inch (LPI), typically 340-450.
4. Focus Height: Ensure the laser is properly focused for the thickness of your material.

Prepare the Anodized Aluminum

1. Clean the surface with a soft cloth to remove dust, fingerprints, or grease.
2. Secure the material in the Glowforge bed using magnets or clamps to prevent movement during engraving.

Perform a Test Engrave

1. Test a small section of your design to verify the settings produce the desired depth and clarity.
2. Adjust power, speed, or focus if necessary.

Engrave the Design

1. Upload your file to the Glowforge interface.
2. Place the anodized aluminum on the cutting bed.
3. Use the camera to align the design with the material.
4. Start the engraving process and monitor the progress.

Using two modalities, you now have a useful and durable tool for reducing spills in your home! Enjoy your new coasters. Cheers!