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Eco-friendly free-size paper models: Integrating additive manufacturing with laser cutting for educational applications.

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Title: Eco-friendly free-size paper models: Integrating additive manufacturing with laser cutting for educational applications.
Authors: Khalilpourazary, Saman1 (AUTHOR) s.khalilpour@mee.uut.ac.ir, Kafili, Farshid1 (AUTHOR)
Source: International Journal of Mechanical Engineering Education. Jul2026, Vol. 54 Issue 3, p583-599. 17p.
Subjects: Rapid prototyping, Mechanical engineering education, Laser beam cutting, Teaching aids, Prototypes
Abstract: Designing and fabricating real models is increasingly popular for enhancing the education of engineers, designers, surgeons, doctors, and students. Additive manufacturing supports this trend but is constrained by part size, raw materials, machine type, orientation of layers, and production time. This study introduces an innovative method combining additive manufacturing with a laser-cutting process to address some of these limitations. First, a 3D model of a pair of similar elliptical gears was designed using engineering software to manufacture paper models. Subsequently, a rectangular paper block was prepared by stacking layers of paper bonded with eco-friendly double-sided tape, mimicking the layer-by-layer approach of additive manufacturing. The desired external geometry of the elliptical gears was achieved via a laser-cutting process to cut the paper block. The simplicity of the fabrication method, environmental compatibility, non-toxicity of raw materials, availability, production of free-size models, and low cost of manufactured parts indicate that this technique can be used as an efficient method for manufacturing physical prototypes. These prototypes make it much easier for students to understand complex mechanical engineering concepts, improving their educational experience. Additionally, The produced samples demonstrated high dimensional accuracy within ±0.01 mm, suitable surface quality, and tensile strength. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Mechanical Engineering Education is the property of Sage Publications Inc. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
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  Data: Eco-friendly free-size paper models: Integrating additive manufacturing with laser cutting for educational applications.
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  Data: Designing and fabricating real models is increasingly popular for enhancing the education of engineers, designers, surgeons, doctors, and students. Additive manufacturing supports this trend but is constrained by part size, raw materials, machine type, orientation of layers, and production time. This study introduces an innovative method combining additive manufacturing with a laser-cutting process to address some of these limitations. First, a 3D model of a pair of similar elliptical gears was designed using engineering software to manufacture paper models. Subsequently, a rectangular paper block was prepared by stacking layers of paper bonded with eco-friendly double-sided tape, mimicking the layer-by-layer approach of additive manufacturing. The desired external geometry of the elliptical gears was achieved via a laser-cutting process to cut the paper block. The simplicity of the fabrication method, environmental compatibility, non-toxicity of raw materials, availability, production of free-size models, and low cost of manufactured parts indicate that this technique can be used as an efficient method for manufacturing physical prototypes. These prototypes make it much easier for students to understand complex mechanical engineering concepts, improving their educational experience. Additionally, The produced samples demonstrated high dimensional accuracy within ±0.01 mm, suitable surface quality, and tensile strength. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
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  Data: <i>Copyright of International Journal of Mechanical Engineering Education is the property of Sage Publications Inc. and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
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        Value: 10.1177/03064190241307646
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        Text: English
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      – SubjectFull: Laser beam cutting
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      – SubjectFull: Teaching aids
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              M: 07
              Text: Jul2026
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              Y: 2026
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