Jango Fett Jet pack (prop for my costume)

Im looking foward to laser cutting all my pieces for a new and imporved jetpack prop.


Cutting pieces like trhese with my jigsaw was very time consuming.My end goal is to have a Prop kit for sale that is completly flat for easy shipping. Im just now learning how to convert my pdf files to vecter.

These are all pics of my first design. Where i need some help, is with the curved parts. i know you can cut them, just not sure how yet. For example this is the rocket that goes on top of the pack.I made it from paper templates.
I need a way top laser cut all these pieces.
Ill keep updating my progress. Oh and this is my final first version.

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Can someone please point me in the right direction for laser cutting curves? Thanks.

I’ll give you a full “Designing for the Laser” lesson next time.

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What do you mean, exactly? Like, curved lines that you can draw in Inkscape?

Or unfolded paper models?

For the first one, you should look up some Inkscape tutorials on youtube or something. I’m really impressed with it, I can do good, accurate work in 2D way faster than in any CAD program. It’s not that hard to get comfortable with workflow, too, once you get used to it.

For the second, I think you might want to check out Pepakura? It’s what papercraft people use to unfold models, and the laser lends itself very very well to the process.
I have never done it myself from scratch, though. Other than @miststlkr’s excellent papercraft workshop at the Bunker.

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So basically the shape thats on the right screen in blue is a template for papercraft. I want to make that out of wood and be able to bend the wood just like paper. The shape in blue forms a cone when cut out and shaped.
The cone in my hand is the shape after cut out.

Your best bet for that would be to slice it into disks and stack them if it has to be wood.

Or maybe look into “live hinges” maybe, but … not really…

Yes living hinges is going in the right direction

They will take a large amount of work to fill and clean if you want a clean cone. Just throwing that out there. We can give one a try, if you’d like.

Hmm, living hinge cone sounds interesting, I have never seen it done. One of the things with them, is they tend to only bend well in one axis, while a cone needs two axes of movement. I think.

Sounds like a great experiment, though, you should totally try it out and report back!

I was wondering what the heck a living hinge was

Wow, pretty neat especially for use with wood. From the wikipedia article

Wood

A variant on the kerf bend can be used to create living hinges in laser cut 
wood. The technique is popular for making light-duty hinges with large radii.
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I’m intrigued by trying to do a living hinge cone with the laser.

I do find some evidence of others having done it.

What kind of minimum thickness can you get away with for the cone?

Mind sharing dimenensions (top & bottom radius, height) - I might take a crack at one in some spare time.

Very cool project.

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First off just want to say thanks for all the interest in my thread! So ill include some pics with dimensions.


Ok so top 2 images are just dimensions of my cone.

Second is after i cut it out, and fold it.
Again thanks for all your input!