I made this at TechShop.
Step 1: Materials and Tools Required
- Four 18" square sheets of corrugated cardboard. You can cut up corrugated cardboard boxes or you can order pre-cut sheets at office supply stores like Staples.
- White Glue.
- A piece of thin but stiff wire.
- A small diameter screw at least 1/4" long.
Step 2: Use 123D to Create the Jupiter 2 Model
Step 3: Add a Center Hole to the Model
Step 4: Export the Jupiter 2 Model in STL Format
Step 5: Create the Cardboard Slices
Step 6: Generate the Files for the Laser Cutter
Step 7: Cut Out and Assemble the Jupiter 2
- The CorelDraw files and a laser cutter were used to cut out and engrave the the parts. I used a 45 Watt Epilog Helix laser cutter at TechShop with the following settings:
- Raster (engraving): Speed 65, Power 20, 300 Dots Per Inch (DPI)
- Vector (cutting): Speed 25, Power 40, Frequency 500 Hertz
- Next, I separated the slices in groups of four slices, used a small screw to align the pieces when glued together as shown the in the first four photos. I then let the glue set (about 5 minutes).
- I then clamped a thin but stiff wire in a vise and used that to align all the pieces as groups of slices were glued together. The fifth through eighth photos show this process.