Magnificent Ten

Howdy! I'm a 12th grader and currently enrolled in Online School of California Virtual Academy @ San Joaquin. As a restless student, I've embarked on an exciting project that combines my love for art and my fascination with various materials while being environmentally responsible by using scraps.

This instruction will guide you through the process of creating stunning text art by collaborating different materials: wood, metal, and 3D printing. Through this project, I aim to explore the unique characteristics and potentials of each material, blending traditional craftsmanship with modern technology to produce visually captivating and innovative text art pieces.

This project highlighted of creating an art that focused a number of 10 which represent special unique inspiration. Number 10 symbolizes perfection of creativity to combine materials into beautiful works of art.

Join me on this creative journey as I share step-by-step instructions and insights on how to bring these diverse elements together into a harmonious state of the art.

Materials and tools that we'll need for this project:

Autodesk Fusion

3D Printer and slicer

PLA Filament (black and orange)

Small Perf board (4 x 6 cm)

7 green LEDs

Coin cell battery 3V

Soldering gun

Solder

Rotary tool

Drill

Orbital sander

Miter saw

Angle Grinder

Aluminum Rod

Punch

Lumber 2x4

Lumber 1x12

To begin, I drafted a sketch design for the number 10 that I envision for this project. This creation will seamlessly integrate the materials of wood, metal, and 3D printing.

Each digit, 1 and 0, incorporates accurately 3D-printed components, which designed in Fusion. First, in the sketch phase, I created a shape of trapezoid for the upper segment of the numeral one (refer to the images for precise measurements). Afterwards, I extruded to form the desired 3D structure.

For the numeral 0, I crafted a semi-circular form using 3D design techniques. In the initial sketch, after forming the semi-circle, I incorporated a rectangular cutout to accommodate an LED fixture. After finishing with the sketch, I continued to extrude the design (refer to the images for precise measurements).

Save the model to STL files and export it. We should have 2 parts for this project. Print it with 0.2 mm of layer height, 50% infill with triangle pattern, with brim and without support. To achieve the amazing infill design, make sure the wall and top and bottom thickness of the shell is at zero mm.

After extensive hours of printing, it's time to refine any imperfections until the surface is flawlessly smooth.

While the 3D printer was in operation, I proceeded to retrieve my angle grinder and began cutting the aluminum rod into precise 20mm segments. I required only five of these segments for this project.

For the 1x12 lumber, I use a compass to make a circle with a diameter of 150 mm and make it half. For the 2x4 lumber, make a mark approximately 90 mm.

Initially, cutting the 2x4 lumber since it is more straightforward to handle. Align the 2x4 against the fence and proceed to make precise cuts through it.

Cut across the semicircle first. At this stage, things started to get complicated. Since I don’t have a router, I used my miter saw to trim the edges, while eyeballing the angle to be as precise as I can. The most challenging part is making the groove for the perf board. I started to cut the groove while sliding it back and forth. Needed to be extra careful not to overcut the groove (it will look bad if that happens) and of course, not to touch the blade for safety reasons.

Sand all the wood's surface until smooth. Next, I carefully sand the semicircle to ensure it aligns with my marking on the wood.

For the lumbers, I needed to use a center punch to ensure accuracy and avoid slippage during drilling. Start drilling from the smallest bit until achieving the desired one. For the 3D printed parts, I used a soldering iron to create an initial hole, and then gradually enlarged it until matched with the diameter of the rod.

Arrange the LEDs to the perf board (refer to the image) and start soldering them. Be careful not to let the positive and negative touch each other.

Phew, after all that hard work, now it's time for the fun part, assembling! Start by inserting the rods into the holes of the wood first. Then install the LEDs into the wood. Finally, assemble the 3D printed into the wood. 

Grab the coin cell battery then boom! And just like that, the LEDs lights up and displaying our hard work. Voila, the project is finished.

It proves it's insane that with scraps around your house, you can create this masterpiece to elevate your home to the next era. Now, it's your turn to try it! Wish you the best!

Thank you for reading to the end. You'll never know how much it means.