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Activity 002: Supervised Laser Cut Execution

Activity ID: U3M3-ACT-002 Duration: 45 minutes Objective: Students will execute the complete laser operation workflow — from startup through cutting to shutdown — producing the name tags designed in Activity 001. Group Size: 2-3 students per laser (instructor supervision required) Materials Cost: ~$3-5 (3mm plywood or acrylic sheet)

Overview

Students operate the laser cutter under instructor supervision, applying the full startup-to-shutdown workflow. Each group member performs a specific role (setup operator, file operator, safety monitor) and rotates. The job produces the name tag batch designed in Activity 001.

Materials & Equipment Needed

  • CO2 laser cutter (instructor-supervised)
  • Material: 3mm birch plywood or 3mm acrylic (approximately 220mm × 70mm per group)
  • Design file from Activity 001 (on USB drive)
  • Focus gauge for the laser
  • Hold-down magnets (2-4)
  • Safety glasses (laser-appropriate)
  • Spray bottle of water (fire safety)
  • CO2 fire extinguisher (location verified)
  • Startup/shutdown checklist (printed)
  • Timer/stopwatch

Instructions & Procedure

Phase 1: Startup Sequence (10 min) Role: Setup Operator performs, Safety Monitor verifies each step

  1. Water chiller: Turn on and verify temperature reads 18-22°C (wait for circulation)
  2. Exhaust system: Turn on and verify airflow (tissue test at intake)
  3. Air assist: Turn on compressor, verify air flows from nozzle
  4. Laser power: Turn on main power, wait for initialization
  5. Safety Monitor checks: Are all four systems running? [ ] Chiller [ ] Exhaust [ ] Air [ ] Power
  6. Safety Monitor verifies: Emergency stop accessible? [ ] Fire extinguisher located? [ ] Spray bottle ready? [ ]

Phase 2: Job Setup (10 min) Role: File Operator configures, Setup Operator handles material

  1. File Operator loads the design file from USB
  2. File Operator verifies layer settings match the material:
  3. Red (cut): appropriate power/speed for 3mm material
  4. Black (engrave): appropriate power/speed for material
  5. Blue (score): low power vector engrave
  6. File Operator confirms processing order: engrave → score → cut
  7. Setup Operator places material on the honeycomb bed
  8. Setup Operator uses hold-down magnets to secure the material flat
  9. Setup Operator sets focus using the focus gauge (verify snug fit)
  10. Setup Operator positions the laser head at the desired origin point
  11. File Operator sets the origin in the software

Phase 3: Pre-Cut Verification (5 min) 15. File Operator runs the FRAMING function 16. All group members observe: does the aiming laser trace within the material boundaries? 17. Safety Monitor verifies: material fully covered? [ ] No obstructions? [ ] Focus set? [ ] 18. If framing reveals any issue: reposition material or adjust origin and re-frame 19. Safety Monitor gives final approval: "Clear to cut"

Phase 4: Job Execution (10 min) Role: Safety Monitor leads monitoring, all observe

  1. File Operator starts the job
  2. Safety Monitor responsibilities during operation:
    • Watch for sustained flame (brief flares at cut points are normal)
    • Monitor exhaust operation (smoke should be pulled away, not accumulating)
    • Listen for abnormal sounds (grinding, clicking, belt slip)
    • Time the engraving phase and compare to the estimated time from Activity 001
  3. ALL group members remain within arm's reach of the EMERGENCY STOP
  4. If any safety concern: press EMERGENCY STOP first, investigate second
  5. Record the actual total job time: _ minutes

Phase 5: Completion and Shutdown (10 min) 25. Wait for the gantry to return to home position 26. Keep the lid CLOSED and exhaust running for 60 seconds 27. Open the lid and assess the results visually (do not remove parts yet) 28. Allow parts to cool for 1-2 minutes 29. Remove finished name tags and inspect: - Did all cuts go completely through? [ ] - Is the engraving clearly visible and centered? [ ] - Is the scoring line visible but not cut through? [ ] - Are the edges clean (minimal charring for wood, polished for acrylic)? [ ] 30. Remove any debris from the honeycomb bed 31. Execute shutdown sequence: - Power off laser → turn off air assist → let chiller run 3 min → turn off chiller → turn off exhaust last 32. Complete the operation checklist and submit to instructor

Discussion Points

  • How did the actual job time compare to the software estimate? Why might they differ?
  • Were there any moments during the job where you considered pressing EMERGENCY STOP? What triggered that thought?
  • Did the engraving appear as expected? How would you adjust settings for the next run?
  • What was the most difficult part of the startup sequence? What could make it easier?

Expected Outcomes

  • Students should successfully execute the complete startup-to-shutdown workflow
  • Name tags should have clean cuts, visible engravings, and scored border lines
  • Safety monitor should identify at least one checkpoint they actively verified during operation
  • Actual job time should be within 20% of the software estimate

Assessment Rubric

Criterion Excellent (5) Proficient (3) Needs Improvement (1)
Startup Sequence All steps in correct order, all verifications completed Correct order with minor verification gaps Steps out of order or systems missed
Job Setup File loaded correctly, settings verified, focus set, framing completed Most setup steps correct, 1-2 omissions Significant setup errors
Safety Monitoring Active monitoring throughout, all checkpoints documented Monitoring present but documentation incomplete Monitoring lapsed or checkpoints missed
Part Quality All cuts through, engravings clear, scoring visible, clean edges Most features acceptable, 1-2 minor quality issues Significant quality problems (incomplete cuts, misaligned engrave)

Safety Considerations

  • Instructor MUST be present and supervising throughout this activity
  • ALL students remain within reach of EMERGENCY STOP during laser operation
  • The lid must remain CLOSED during all laser firing
  • If flame is observed: EMERGENCY STOP first, then assess
  • No one reaches into the machine while the laser is powered on
  • Freshly cut acrylic edges may be sharp — handle carefully
  • Freshly cut wood may still be hot — allow cooling before handling
  • Exhaust must be verified running BEFORE the first laser pulse

Last Updated: 2026-03-19