This video documents the process of creating a 3D Benchy boat model from stacked, laser-cut cardboard layers, driven by the challenge of recreating functionality previously offered by the now-discontinued Autodesk "123D Make" software. The creator details a comprehensive workflow utilizing various open-source tools: scaling the 3D model in PrusaSlicer, strategically adding alignment dowel holes in Blender to overcome software limitations, slicing the model into 2D layers with Kiri:Moto, and then organizing and numbering these layers in Inkscape. The video culminates in the laser-cutting process using the xTool S1 machine, highlighting its safety features and integrated software, followed by the final assembly. The creator emphasizes the time-intensive nature of preparing the digital files and advocates for the development of more user-friendly open-source tools for such fabrication projects.
Summarizing the Cardboard Benchy Creation:
0:00 Replicating 3D Models in Cardboard: The video introduces the ambitious goal of creating a 3D Benchy model by laser-cutting and stacking layers of cardboard, a process previously simplified by Autodesk's "123D Make" which is no longer available.
0:26 The Challenge of Discontinued Software: The creator explains that "123D Make" (later "Slicer for Fusion 360") was an excellent, free tool for converting STL models into stackable or interlocked slices, providing assembly instructions and numbered parts, but Autodesk discontinued it.
1:10 The Open-Source Plan: A new workflow is outlined: scaling the STL model (4x larger), generating laser-cut drawings (SVGs) with dowel holes and numbered parts, optimizing layouts for cardboard sheets, laser cutting, and then gluing.
1:54 Scaling and Initial Slicing (Kiri:Moto): PrusaSlicer is used to scale the Benchy. "Kiri:Moto," an open-source, browser-based slicer, successfully generates SVG layers but initially lacks dowel support, numbering, and produces a single, unorganized large layout.
2:49 Adding Dowel Holes (Blender Solution): To ensure proper alignment of the stacked layers, especially for complex sections, dowel holes are crucial. After PrusaSlicer failed, Blender (a 3D modeling software) was used to manually punch these holes (e.g., on the cabin corners, hull sides, keel, and chimney) into the STL model before re-slicing.
4:29 Preparing Layouts and Numbering (Inkscape): The large SVG file from Kiri:Moto is then broken down into multiple sheets using Inkscape. Layer numbers are added to each piece for assembly guidance, and distinct colors are assigned for laser engraving (numbers) and cutting (outlines).
5:18 Laser Cutting with xTool S1: The xTool S1 laser machine, along with its proprietary "xTool Creative Space" software, is used for cutting. The creator highlights features like automatic focus, real-time laser head tracking on screen, safe enclosed operation (no glasses needed), and effective smoke extraction.
7:25 Assembly and Final Product: The 30 layers of 3mm cardboard are cut and glued together, resulting in a successful 3D cardboard Benchy. The creator notes that gluing took significantly less time (15 minutes to an hour) than the digital preparation (a whole day).
8:45 Call for Better Open-Source Tools: The creator expresses a desire for more user-friendly open-source software tools to streamline the model preparation and slicing process, making laser cutting more accessible to a wider audience, and encourages community input for new software recommendations.