Recently, I've been trying to improve how I document my various projects. A great way to do this is by creating Instructables for each of them to reflect back on and even get some advice from other experienced creators. However, one thing I continue to struggle with, is getting good videos/time lapses to go along with my builds. As such, I've used laser cutting to make this simple and versatile stand to help with documenting my projects!

This is a super simple and beginner friendly laser cutting project for anyone to try

Supplies

CAD software (I use Fusion360)
3mm MDF
Felt pieces
Scissors or hobby knife

Step 1: On Paper Drawing

Before I get stuck into any CAD on little projects like these, I like to start with some simple drawing to get an idea where to start, and choose some basic measurements. You can go straight into CAD if you prefer, but I think it's a good idea to get an idea of where you're heading.

Step 2: Choosing Size for Tabs

Holding the final piece together will be a series of interlocking tabs and slots. It would be ideal if these joints were tight as this would mean no glue will be required later which makes the process easier and the finished product even better looking! To get this perfect fit it is important to understand that whilst lasers cut very fine lines, some material is still lost. We call the width of this material the kerf and it is often less than 1mm thick. In my experience, a tight fit can be achieved using a kerf of 0.2mm for the 3mm MDF board and Trojec Laser cutter I’ll be using; however, this can vary from 0.1mm – 2mm depending on your materials, laser cutter, and its setup so it is important to research this step. As both ends of the slot will have this kerf, you’ll have to account for it twice equating to 0.4mm for each extrusion.

I’m using a tab length of 20mm and 10mm, so I’ll only be cutting a slot length of 19.6mm and 9.6mm. This should ensure a perfect and snug fit for my components

Step 3: Side Plates CAD

Now we have a basic idea of what we're trying to make, it's time to move into our software. I started with the end plates, replicating some simple geometry of my drawing. We want to sure the center of gravity will fall comfortably between the two legs of the design so it will be stable once we add our phone or device to it, so just be mindful of where the slots for the supporting plates will go.

For the slots, I chose lengths of 10mm and 20mm earlier for the base and back plates respectively, but these values can change to whatever suits your side plate outlines. I found it easiest to construct the top slot with an 80 degree angle to horizontal and then used a construction line to base the position of the smaller slot. Construction lines can be accessed on the sketch Palette on the right hand side after selecting the line tool.

Step 4: Supporting Plates CAD

Now's for the supporting plates. This again is a really simple construction just using the line tool in Fusion360. Because of the simple symmetric shape of these plates, it's good practice to design half first and then use the mirror tool to complete the sketch - this is really easy in Fusion360, just add a construction line at the midpoint, then select everything to mirror, click the mirror tool, and select the construction line you made down the center to mirror.

Step 5: Exporting DXF

Next up is exporting our files ready for laser cutting or 3D printing. Since our side panels used splines to create curves for the edges, it is good practice to convert these to polynomials during our export since some software has issues computing spline curves. In Fusion360, this can be done easily using the DXF Spline to Polyline Add-on created by AutoDesk, Inc. After the quick install – it’s as easy as selecting the "Export to DXF (Splines to Polylines)" option under "create" in the sketch menu.

Link to Add-on:

https://apps.autodesk.com/FUSION/en/Detail/Index?id=4611814297957846949&appLang=en&os=Win64&autostart=true&_ga=2.24002623.484475246.1700607752-1442530280.1698811017

Step 6: Laser Cutting

This step is the fun one! Time to get laser cutting

Once you have your completed DXF files, you're ready to set up for laser cutting! I used a Trotec laser cutter for this project, so the process was as easy as importing my selection into CorelDraw – and then printing the page to Trotec Job Control. Just make sure to print two side pieces!

It's always important to make sure your page is the right size for your laser cutter dimensions so that everything runs smoothly and predictably, and components don't go beyond the workable area.

Step 7: Adding Felt Pieces

Next we'll add a little touch to nicen the final product a little. the felt pieces I'm using have an adhesive already on the back so it's as easy as cutting them to size, peeling off the back sheet and sticking them on the back and bottom plate where your device will rest.

Step 8: Putting It Together

Now we have all of our pieces ready for construction, it's as easy as sliding it into place! The kerf adjustments that we made earlier should mean that the parts press into place firmly and will hold their shape without any glue necessary. Some persuasion might be needed if they're a little tight but they should be able to just be tapped in. If not, a little bit of sanding should do the trick

Step 9: Files

And that's it, the DXF files I used for this simple stand are attached here for you to get started with straight away, and a photo of my stapler using it!