This week I designed and sent off requests for new laser cut cases — one wood sheet from Ponoko, and an acrylic sheet from Pololu.
Material: One surprise for me — I made a slightly bigger case, and adding on 1″ to each dimension roughly doubles the material. For instance, take a 4″ square, that’s 16 square inches of material. A 5″ square is 25 inches of material. This can get out of hand pretty quickly!
Speed: On the recommendation of a friend, I browsed onto Pololu.com, which offers custom laser cutting services. Pololu doesn’t have plywood or bamboo in stock, but they do have 1/4″ acrylic and promise a 3 day turnaround time vs Ponoko’s 11-15 day turn time. Of course, I pay extra for the speed but for prototyping it’s well worth it. I placed my Pololu order on Thursday afternoon and it shipped Friday!
Prototyping: Designing laser cut cases sure can be a pain in the butt. I spent all day on July 4th simply designing a bigger OpenPCR case with bolted edges rather than teethed edges. My workflow goes from the overall design in Google Sketchup, adding features like teeth, bolt holes, nodes, and radii. Then importing that into Illustrator, adding additional teeth, and the submitting it to be cut.
This is fine if you’re putting together a one-off design, but for prototyping, changing, and updating designs I certainly could use some better tools. A good friend of mine has the same issues. If you have any suggestions or experience in converting Sketchup designs to Illustrator for Ponoko/laser cutting, let us know!