Large Laser Cut Vernier Caliper

Oversized, fully functional 33" vernier caliper designed in Fusion 360, laser-cut in MDF with PETG brackets, and Python-generated scales achieving 0.01" resolution.

I designed and built a large-format vernier caliper as an educational tool that demonstrates precision measurement concepts at a scale that’s easy to see and understand.

Design and CAD

  • Created the caliper beam outline and bracket geometry in Fusion 360
  • Exported brackets as STL for printing; caliper outline as DXF for laser cutting

Fabrication

  • Laser-cut and 3D-printed the vernier parts in 1/4” MDF
  • Printed the brackets in PETG for durability and stiffness
  • Engraved the scales after cutting and completed assembly

Scale Generation

  • Wrote a short Python script to generate an inch rule with 0.1” main divisions
  • Generated a matching vernier scale to achieve 0.01” measurement resolution

Result

  • Fully functional up to 33 inches
  • Measures to 0.01”
  • Highly effective as a hands-on instructional/learning tool