Step 3 – 3D paper prototype
Let’s now move from 2D to 3D space. We’ll cut and score a piece of cardstock to form a 3D version of your character. In order to do so, you’ll have to deconstruct it into simple, foldable shapes. Explore different options on paper/sketches before moving to Illustrator.
Here are some templates you can scale and edit in Illustrator to recreate your model:
- Square box
- Triangle
You may also explore The Paper Foldables site for inspiration.
The height of your assembled model should be between 3 and 6 inches.
Make a first draft in Illustrator. Print it out on an inkjet printer and put it together with scissors and tape. Don’t worry about making perfect cuts/folds. You just want to test the measurements/proportions before sending the file to the vinyl cutter.
You’ll follow the same settings as for step 2. Use as 12″ x 12″ documents as you need to comfortably fit all your shapes. You’ll also need to add score lines for the folds. Keep your Illustrator file organized: make sure you create separate layers for different elements and label them clearly.
- Stroke type for score: dashed (12 pt dash | 24 pt gap)
Make an appointment with your lab manager and give him/her the exported .DXF file. Watch the machine do its work! Once you have your vinyl cut design, fold it and glue it together.
Step 4 – 3D cardboard model
Now that we’ve iterated on and tested our model, we’re ready to scale it up, add details and use sturdier materials. We’ll use the laser cutter to cut and engrave cardboard.
Scale up your 3D paper prototype. The height of your assembled model should be between 8 and 15 inches. The best way of testing the dimensions is to scale up the Illustrator file you created for the 3D paper prototype, send it to the laser cutter and see if you need to change anything else.
Think of the engraving feature as “drawing”. The laser beam will move faster along these lines, thus creating a mark without cutting through the material. You may bring back some of the details you had in your sketch (eyes, hair, clothing details etc.)
These are the settings you should use in Illustrator to prepare the file for the laser cutter:
- 24″ x 12″ Artboard (use as many Artboards as you need to comfortably fit all your shapes)
- Strokes for cuts: RGB (0,0,0) | #000 | 0.001pt
- Fill and strokes for raster engraving and scoring: RGB (0,0,0) | 0.25 pt (or above)
- Make sure there are no double or overlapping shapes. Use the Pathfinder window to combine shapes if necessary.
- You do not need to export to .DXF, the laser cutter accepts AI files.
Make an appointment with your lab manager. Give him/her your .ai file and watch the machine do its work! Once you have your laser cut/engraved shapes, fold them and use hot glue to fastened them.
