Fusion Generator Laser Cut Flatpack Details

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(Kresty's build uses these)

The Laser Cut Files are a modified version of Savage's flatpack above. They are intended for lasers with 18x24" beds and will not work to CnC (parts are touching, so no room for the CnC bit).

Since the bed size is smaller, there are 2 1/16" sheets and 4 1/8" sheets. Also some parts had to be split into two pieces.

Several of the rings I combined Savage's halves to make complete circles. Including one of the grills has 2 half rings combined (so these plans have 18 half rings and one full ring)

Additionally, there are simple files for the translucent lens(es), though you'll need 2 each - they're just over 24" long so won't fit on the laser bed (ok, won't fit without a ton of waste, you could cut them diagonally at full size).

The laser files generally have:

  • A thin < 0.1pt black RGB 00 00 00 line for the laser cut edges
  • Red RGB FF 00 00 areas to etch the grooves.
  • Additional colors for lettering that does not need to be cut/etched.


Grill Edges

Savage specified that the edges are rounded with his CnC. Since the laser doesn't do that, we'll need to round the edges ourselves. Sandpaper should work. This is the blue area of each grill vane.

Notches

The original plans have notches for the lenses and grill cylinder to fit.

The laser plans include red etchable areas, however that will require 30-40+ additional minutes for each of those 3 sheets for the 3 etched parts. If you choose to do that, try to get them at least 1mm deep, but don't burn through the 1/8" styrene. The melting styrene also means that these notches are kind of U shaped and may require hand finishing to square off the bottom of the hole.

An alternative to the notches would be to cut an additional circle so the parts could rest against that instead of sliding into the notches. That might be wiser, however those circles are not included in these plans.

File List

 Flat Pack Parts.cdr - My original CorelDraw X8 file with all parts (15 day trials available if you need to edit something)

Primary version. Thin black lines for vector cutting. C, D & E also have red areas for raster etching if desired (see notes about notches above). Cut the One Sixteenth files from 1/16" or 1.5mm styrene, cut the One Eighth files from 1/8" or 3mm styrene. 

 2x Lower Diffuser - Optionally, cut two of these from something like cast acrylic light diffuser panels.
 2x Top Diffuser - cut two of these from something like cast acrylic light diffuser panels.
 Laser Sheet A 24x12 One Sixteenth Fusion Generator
 Laser Sheet B 19x11 One Sixteenth Fusion Generator
 Laser Sheet C 24x18 One Eighth Fusion Generator
 Laser Sheet D 24x18 One Eighth Fusion Generator
 Laser Sheet E 24x18 One Eighth Fusion Generator
 Laser Sheet F 20x6 One Eighth Fusion Generator

Alternate versions without text or other annotations in case you need them for something like the Epilog. These only have thing black lines for vector cutting and big red areas for raster etching. 

 Alt Etch Laser Sheet C 24x18 One Eighth Fusion Generator.pdf
 Alt Etch Laser Sheet D 24x18 One Eighth Fusion Generator.pdf
 Alt Etch Laser Sheet E 24x18 One Eighth Fusion Generator.pdf
 Alt Etch Laser Sheet F 20x6 One Eighth Fusion Generator.pdf

Epilog-type software

  • Vector cut the 0.1pt black lines. I did this at 16% speed, 100% power on our new 80watt laser.
  • Optionally etch the grooves with the "alt" plans for the 3 grooved sheets - the alt versions have the text, etc removed so they can be etched. I used 18% speed, 1000hz, but it took absolutely forever - 40+ minutes just for the etch.

Universal-type software

  • Vector cut the RGB 000000 black lines.
  • Optionally etch the RGB FF0000 red areas.
  • Text, etc, are other colors: Do not cut or etch anything other than the red/black!
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