Pass first. Then weigh in.
Structural qualification is pass/fail. Among the structures that pass every requirement, the lowest total assembled mass wins.
POE Unit 0 • Lesson 0.8
Laser Manufacturing
Focus question: How can we remove unnecessary acrylic while keeping the top and bottom plates strong enough for the final qualification test?
Challenge Rules
CubeSat Lightweight Structure Challenge
Every team works inside the same architecture and material limits. Your engineering advantage comes from how efficiently you use them.
- Maximum assembled envelope: 4 in × 4 in × 4 in, including hardware.
- Top and bottom: laser cut from the team’s single 4 in × 12 in × 1/8 in acrylic sheet.
- Sides: remain open; no side panels.
- Primary frame: 3D printed using the same teacher-selected filament material for every team.
- Assembly: M3 screws for all primary structural connections; structural glue is not permitted.
- Serviceability: the structure must be able to be disassembled and reassembled with normal hand tools.
- Competition: the lightest structure that passes every qualification requirement wins.
Lesson Targets
What You Will Be Able to Do
I can create laser-ready top and bottom plates, nest them efficiently, and verify the material and machine workflow before cutting.
Laser Cutter Certification + 4 in × 12 in cutting layout + laser-ready files
Both required plates fit on the single 4 in × 12 in × 1/8 in acrylic sheet, include M3 interfaces, and are approved before cutting.
Activity Flow
How Today Advances the CubeSat
1. Finalize the plates
Add M3 holes and lightening features without weakening critical connection zones.
2. Nest on the stock sheet
Place all laser-cut parts inside one 4 in × 12 in sheet.
3. Certify and cut
Complete the laser certification workflow and instructor approval before manufacturing.
Material Budget
One Sheet. Two Required Plates.
The acrylic allocation is a hard constraint, not an unlimited supply.
4 in × 12 in × 1/8 in Acrylic
Every team receives the same sheet size, material, and thickness for its official structure.
Top + Bottom
Both required plates must come from this sheet. Additional approved laser-cut parts must also fit within the same allocation.
Remove Material Intentionally
Lightening holes and cutouts can reduce mass, but preserve sufficient material around M3 joints and structural load paths.
Project Milestone
Today’s Required Deliverable
Laser Manufacturing Release
- Laser Cutter Certification completed.
- Top and bottom plate geometry finalized.
- Both plates nested on a single 4 in × 12 in × 1/8 in acrylic layout.
- M3 clearance holes and connection geometry verified.
- Kerf and material identification considered.
- Laser-ready vector file(s) submitted and approved.
Engineering Decision
Document the Reasoning
What did your team decide today?
What measurements, requirements, comparisons, calculations, or manufacturing information support that decision?
Why does that evidence make the decision appropriate for a lightweight structure that still has to qualify?
Resources
Lesson Resources
Laser Cutting Certification
Complete the laser certification before manufacturing the official acrylic plates.
CubeSat Unit 0 Overview
Review the complete challenge sequence, project rules, deliverables, and competition objective.
Principles of Engineering
Return to the POE hub for units, course resources, and certifications.