Introduction: Week 2: Press-Fit Laptop Riser (MAT238)

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In this project, I designed and built a laser-cut laptop stand with press-fit components.

Supplies

  • Fusion 360
  • 1/4" Plywood
  • Laser Cutter

Step 1: Concept Sketch

Most laptop stands are one-dimensional and have no other uses, so I wanted to create something that is multi-use, and doesn't look like a laptop stand when not in use. The goal with the curves was to make it look like a cylinder that had been deformed.

Step 2: CAD Sketch

To design all the legs, I created a single sketch for all seven. Most dimensions are function-based, so I can change parameters like material thickness, and the model will universally change to account for the new material.

Step 3: CAD Assembly

I pieced together the model in an assembly to confirm that my design would be assemblable once laser cut.

Step 4: Tuning for Press-fitting

To account for the kerf of the laser cutter, I created a test block with pegs and holes of varying designed overlaps. Laser-cut pieces will have a different dimension than the design file due to the burned-off material. This means pegs should be laser-cut larger designed for, and holes smaller. A 0.15mm overlap between the peg and hole had my desired friction fit.

Step 5: Laser-cut Layout

All the components in the assembly were converted to DXF files and were all put into one Illustrator file to be laser cut.

Step 6: Laser Cutting

The file was sent to the laser cutter which cut the 1/4" plywood.