Activity 001: Design File Preparation and Software Setup¶
Activity ID: U3M3-ACT-001 Duration: 40 minutes Objective: Students will prepare a multi-layer design file for laser cutting and engraving, configure color layers, and set up the job in the laser software. Group Size: 2-3 students per computer station Materials Cost: ~$0 (software-only design activity)
Overview¶
Students create a laser-ready name tag design that includes both vector cut paths and raster engraving areas. They practice color coding, layer assignment, and job configuration in the laser software, preparing a file that is ready for actual cutting in Activity 002.
Materials & Equipment Needed¶
- Computer with vector design software (Inkscape or Adobe Illustrator)
- Laser control software (LightBurn preferred, or RDWorks)
- Design template file (optional — blank rectangle at 70mm × 30mm)
- Color reference chart (posted at each station)
- File setup checklist
Instructions & Procedure¶
Phase 1: Design Creation (15 min) 1. Open the vector design software 2. Create a new document with dimensions matching the laser bed (units: mm) 3. Design a name tag with these elements: - Outer rectangle: 70mm × 30mm with 3mm corner radius — this will be the CUT outline (color: RED, RGB 255,0,0) - Mounting hole: 5mm diameter circle, positioned 5mm from the left edge, centered vertically — this will be an INTERIOR CUT (color: RED) - Student name: Text, 8mm height, centered — this will be RASTER ENGRAVED (color: BLACK, RGB 0,0,0) - Decorative border line: 2mm inside the outer rectangle — this will be SCORED/VECTOR ENGRAVED (color: BLUE, RGB 0,0,255) - Optional: Add a small graphic or logo for engraving (BLACK) 4. Convert all text to outlines/paths (text fonts may not transfer to the laser computer) 5. Verify all cut paths are CLOSED (no gaps in outlines) 6. Check for duplicate lines: select all, check object count 7. Save as SVG and/or DXF
Phase 2: File Import and Layer Configuration (10 min) 8. Transfer the file to the laser software (LightBurn or RDWorks) 9. Import and verify: all elements visible, correct scale (70mm × 30mm) 10. Verify color layer assignments: - Red layer: Mode = "Line" (vector cut), Power = 70%, Speed = 12 mm/s - Black layer: Mode = "Fill" (raster engrave), Power = 30%, Speed = 300 mm/s, DPI = 400 - Blue layer: Mode = "Line" (vector engrave/score), Power = 15%, Speed = 100 mm/s 11. Set processing order: Black (engrave) FIRST → Blue (score) SECOND → Red (cut) LAST 12. Verify the "inside cuts first" option is enabled for the red layer
Phase 3: Job Layout and Verification (10 min) 13. Position the design on the virtual work area to match where the material will be placed 14. Use the array function to create a 3×2 grid (6 name tags) with 3mm spacing 15. Calculate total material needed: approximately 220mm × 70mm of 3mm acrylic or plywood 16. Run the virtual preview/simulation to verify: - Engraving runs first across all 6 pieces - Scoring runs second - Internal holes cut before outer rectangles - Estimated total job time (record this) 17. Export/save the final job file ready for the laser
Phase 4: Peer Review (5 min) 18. Swap stations with another group 19. Review their file for common errors: - Are colors EXACTLY correct (check RGB values)? - Are all cut paths closed? - Are there any duplicate lines? - Is the processing order correct? - Are settings reasonable for the material? 20. Provide written feedback on their checklist
Discussion Points¶
- Why must text be converted to outlines before sending to the laser?
- What would happen if the processing order was reversed (cut before engrave)?
- How does the array spacing (3mm gap) affect material waste vs. heat management?
- If you needed to make 100 name tags, how would you modify the workflow?
Expected Outcomes¶
- Design files should have exactly 3 color layers with correct RGB values
- All cut paths should be closed with no duplicates
- Processing order should be: engrave → score → cut
- Array layout should fit within the material dimensions with appropriate spacing
Assessment Rubric¶
| Criterion | Excellent (5) | Proficient (3) | Needs Improvement (1) |
|---|---|---|---|
| Color Coding | All three colors exactly correct RGB, assigned to proper operations | Colors mostly correct, minor assignment errors | Incorrect colors or missing layers |
| File Quality | No open paths, no duplicates, text converted, correct dimensions | Minor file issues (1-2 open paths or duplicates) | Multiple file quality issues |
| Layer Settings | Power, speed, mode all correctly configured for the material | Settings present but not optimized | Missing or incorrect settings |
| Layout and Order | Correct array layout with proper processing order | Array set up but processing order incorrect | No array or significant layout issues |
Safety Considerations¶
- No laser operation in this activity — software and design only
- Ensure ergonomic workstation setup
- Save files frequently to prevent data loss
Last Updated: 2026-03-19