Here's what you'll need:
• A sheet of 1/4" thick double walled corrugated cardboard. (For demonstration purposes I painted one side of my corrugated cardboard black.)
• Adobe's Illustrator or other comparable vector graphics authoring tool
• Access to a Laser cutter
• White glue and a sponge brush to apply it
Prepare the Image Files
I use Adobe's Illustrator CS4 as my vector image authoring tool. You'll want to do the equivalent in whatever tool you use.
Concentric 2D Morphing Shapes
• Create a 6.5x10" file
Step 1: Make an Oval
Step 2: Make a Star
Step 3: Blending Your Oval & Star
Step 4: Blending Magic!
• You now have a special "Blend Tool" cursor icon -- click it once on the top horizontal mid-point of the oval, then click it once on the top horizontal mid-point of the star ... and Voila! You've created 12 morphing shapes.
Step 5: Making the in Between Shapes Vector
Step 6: Editing Shapes
Step 7: SAVE Files, Part 1 & 2
To construct the solid object you'll need a second set of concentric shapes that offsets alternate layers of the first set. To do this simply SELECT ALL and:
• Change the width FROM 10 TO 9.7
• Change the height FROM 6.5 TO 6.2
• Save this file AS: "Concentric-2D-Morphing-Shapes_part-2-of-2"
Convert your .ai files to .plt
Adobe's Illustrator CS4 does not export a plotter .plt format, but Makerplace provides me with a copy of Corel Draw 5, which does.
• In Corel Draw 5 open the Illustrator.ai, which is saved to version 8, and simply save as .plt, or an equivalent file format that works with your laser cutter.
I have included the Adobe's Illustrator (.ai) files used for this project.
Step 8: Settings to Laser Cut Your Shapes
• Import your "Concentric-2D-Morphing-Shapes_part-1-of-2.plt" file
• Set your cut option. On the 100 watt laser at Makerplace, my settings were Speed: 20, Power: 90; Corner power: 55
Step 9: Laser Cut Your Shapes
• Repeat the above step for your "...part-2-of-2.plt" file.
Step 10: Prep for Assembly
• Dilute your white glue. (50% glue with 50% water)
• You will only be using the inner-most solid piece from the larger set of shapes (part-1-of-2) and you won't need to put glue on this shape, so set it aside.
Step 11: Assembly
• With the glue still wet, alternately stack the outer piece of the part-2-of-2 set on top of the corresponding part-1-of-2 piece. Be careful to center each piece in place before stacking the next piece.
• When all pieces are stacked (don't forget the bottom inner-most solid piece you previously set aside) clamp or place weight on your stacked object to compress it while the glue dries.
Step 12: Voila!
Thank you Makerplace for providing the space, tools and support in developing this novel idea.