Laser Cut Prototype Process Log
Design
The goal of this project was to design a laser-cut laptop stand that is stable, easy to assemble, and practical for daily use. I personally needed a laptop stand, so this project was also an opportunity to design something I could actually use.
During the design process, I actually applied basic physical concepts from mechanics and structural knowledge. One key assumption I made was that even relatively fragile materials, such as thin boards (e.g., cardboard or plywood), can still be used to build a structure strong enough to support a 15–16 inch laptop (~1.5–2.0 kg) if the geometry is designed properly.
Another assumption was that it prefers a product that does not require tools, so I decided to use a friction-fit system instead of screws or glue
I explored different structural forms at the beginning. A simple rectangular frame did not feel stable enough, so I shifted to a triangular side panel design, since triangles are more effective at distributing force and preventing deformation under load.
I also made several practical decisions:
- I used an angled surface (~15°–20°) to improve comfort when typing and viewing the screen, which is also an ideal position for me.
- I designed the top using multiple long strips, which reduces material usage and helps with heat dissipation
- I used a slot-based connection system, matching the material thickness (3 mm), so that all parts can be assembled without glue or tools
Overall, the design focuses on making a structure that is simple, stable, and easy to build, while testing how far material and structure alone can support real-world use.
Sketches
At the beginning, I built a rough physical model using A4 paper to explore the overall structure and feasibility of the design. This initial prototype helped me understand how different parts could be assembled and whether the material could support the intended function.
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Based on this model, I then refined and developed a more detailed sketch. The final design consists of five long supporting strips and two main panels, which are connected through slot-based joints. This interlocking system allows the structure to be assembled without adhesives while maintaining stability.
Prototype
For the prototype stage, I completed three iterations using laser cutting. In both the first and second iterations, all components were successfully cut, but I made critical mistakes related to the slot dimensions.
Iteration 1
In the first iteration, I made an error while adjusting measurements in Cuttle, which led to a 1.5 mm deviation in the slot size. This small inaccuracy prevented the long strips from being inserted into the slots, resulting in a failed assembly.
Iteration 2
In the second iteration, the slots were too large, which caused the long strips to fit loosely into the main panels. As a result, the overall structure was unstable and could not hold its form properly.
Final iteration
After learning from these mistakes, I carefully remeasured and refined the slot dimensions in the third iteration. I set the slot size to a length of 23 mm and a width of 3 mm. With these corrected measurements, all parts fit tightly together, and the final assembled structure became stable and was able to support the weight of a laptop.
Analysis
Through this assignment, I learned the importance of precision, iteration, and testing in the design and prototyping process. One of the key things that worked well was the overall structural concept. The idea of using interlocking slots to connect the long strips and main panels proved to be effective once the dimensions were correct. In the final iteration, the structure was stable and able to support the weight of a laptop, which validated my initial design assumption.
However, several aspects did not work well in the earlier stages. The biggest issue was inaccurate measurements, especially in the slot dimensions. Even small errors, such as a 1.5 mm deviation, led to major problems like parts not fitting or the structure becoming unstable. This showed me how sensitive laser-cut designs are to precision and how important it is to carefully check dimensions before fabrication. Meanwhile, I also learned that broadening the usability and feasibility of the product is important for prototyping.
Feedback
During the in-class critique, my peers praised my slot design and precise measurements, which made the structure very stable and strong. They also liked the overall shape and noted that it can hold a 16-inch laptop. However, they pointed out that the tilt angle is too high, which makes typing uncomfortable, and suggested reducing the angle. They also recommended increasing the width of the slot that holds the laptop, since the current size may not fit laptops with cases or thicker devices. In addition, they suggested adding a panel underneath the stand to hold a keyboard. They also suggested reducing the overall length of the stand, since it is currently designed mainly for a 16-inch laptop. By shortening the length, the design could also fit smaller devices like 14-inch laptops or iPads, which would improve its feasibility and usability.
