Laser Cutting Teaching Assistant, Fall 2025

by Aymen Aiblu  | December 05, 2025 | Ottawa, ON - Canada

During the first year of my PhD journey at Carleton University, I worked as a Teaching Assistant in the Fabrication Lab (Fab Lab). While my primary focus as a doctoral candidate is research, the Fab Lab provided a unique laboratory of a different kind, one where the theoretical designs of students collide with the physical realities of material and machinery. This archive documents the workflow, the safety protocols, and the intricate results produced during these sessions. 

The Fab Lab is the heartbeat of production at the school. It is a space defined by the hum of ventilation systems and the precise movement of machinery. As a TA, my role extended beyond simple supervision, it was about fostering an environment where students felt confident handling industrial-grade equipment. Safety was paramount. We operated under strict protocols, such as the clear directive that Only Operator Loads and Unloads, ensuring that students respected the machinery. The lab is equipped with robust Craftex systems and laser cutters that require constant vigilance regarding airflow and settings.

One of the most rewarding aspects of this role was guiding students through the digital-to-physical translation. The process begins in the software realm. We utilized vector-based software (Adobe Illustrator) to prepare files, ensuring lines were clean and layers were correctly set for cutting versus etching. I assisted students in navigating the interface between their design intent and the machine's capabilities. This involved:

• File Preparation: Checking vector paths, color mode and level, as well as geometry in the software to ensure the laser would interpret the data correctly.

• Machine Setup: Teaching students how to configure the VLS3.50/60DT Control Panel , estimating run times, and managing power/speed settings.

• Calibration: A crucial technical lesson was setting the Z-axis focus. We drilled the importance of "Set Z in 'GO' First" and adhering to maximum thickness limits (Max Z 2.4" with a 2.0 Lens) to prevent material damage or fire hazards.

The output of these sessions was often stunning. We explored complex massing models, cutting precise elevations for what appear to be industrial or institutional buildings with saw-tooth roof structures. The precision of the laser allowed for perfect assembly of these 3D forms from 2D sheets. Perhaps most resonant with my own research interests in heritage and geometry were the explorations into intricate patterning. We successfully fabricated high-density geometric screens and tessellations. These pieces required the machine to cut complex cellular structures and star patterns, reminiscent of traditional mashrabiya or biological structures. Watching these patterns emerge from a blank sheet of material was a highlight for the students, the moment we lifted a perfectly cut, lace-like sheet from the laser bed was always met with excitement and relief.

​Beyond the laser cutting process, we engaged in physical assembly and wood processing. The below photos document our work with clamped molds and stacked structural elements, exploring the tectonic qualities of raw timber and stone aggregates.

Overall, serving as a TA in the Fab Lab was a reciprocal learning experience. While I helped students through the technical hurdles of file types, focus heights, and safety toggles, they reminded me of the joy of making. Seeing a student's anxiety about a complex file turn into pride when the physical model was assembled, tangible, precise, and beautiful, was incredibly fulfilling. This archive stands as an award to those hours spent between the computer screen and the laser bed, bridging the gap between architectural thought and architectural artifact.