Laser Hacks

608 Articles

A Mechanical Laser Show With 3D-Printed Cams And Gears

June 15, 2017 by 22 Comments

Everyone knows how to make a POV laser display — low-mass, first-surface mirrors for the X- and Y-axes mounted on galvanometers driven rapidly to trace out the pattern. [Evan Stanford] found a simpler way, though: a completely mechanical laser show from 3D-printed parts.

The first 10 seconds of the video below completely explains how [Evan] accomplished this build. A pair of custom cams wiggles the laser pointer through the correct sequences of coordinates to trace the desired pattern out when cranked by hand through a 1:5 ratio gear train. But what’s simple in concept is a bit more complicated to reduce to practice, as [Evan] amply demonstrates by walking us through the math he used to transfer display shapes to cam profiles. If you can’t follow the math, no worries — [Evan] has included all the profiles in his Thingiverse collection, and being a hand model software guy by nature, he’s thoughtfully developed a program to automate the creation of cam profiles for new shapes. It’s all pretty slick.

Looking for more laser POV goodness? Perhaps a nice game of laser Asteroids would suit you.

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Drop-in Controller For EBay K40 Laser Engraver Gets Results

June 10, 2017 by 42 Comments

[Paul de Groot] wrote in to let us know about a drop-in controller replacement he designed for those economical K40 laser engravers that are everywhere on eBay. With the replacement controller, greatly improved engraving results are possible along with a simplified toolchain. Trade in the proprietary software and that clunky security dongle for Inkscape and a couple of plugins! [Paul] felt that the work he accomplished was too good to keep to himself, and is considering a small production run.

Laser engravers are in many ways not particularly complex devices; a motion controller moves the head in x and y, and the laser is turned on or off when needed. But of course, the devil is in the details and there can be a surprising amount of stuff between having a design on your screen and getting it cut or engraved in the machine. Designing in Inkscape, exporting to DXF, importing the DXF to proprietary software (which requires a USB security dongle to run), cleaning up any DXF import glitches, then finally cutting the job isn’t unusual. And engraving an image with varying shades and complex dithering? The hardware may be capable, but the stock software and controller? Not so much. It’s easy to see why projects to replace the proprietary controllers and software with open-source solutions have grown.

Cheap laser engravers may come with proprietary controllers and software, but they don’t need to stay that way. Other efforts we have seen in this area include LaserWeb, which provides a browser-based interface to a variety of open-source motion controllers like Grbl or Smoothieware. And if you’re considering a laser engraver, take a few minutes to learn from the mistakes of other people.

Holograms Can’t Be Too Thin

June 3, 2017 by 28 Comments

We’ve seen the 3D phone fad come and go, with devices like the Evo 3D, that used a parallax barrier to achieve autostereoscopy (that is, 3D viewing without glasses). These displays aren’t holograms, they are just showing your eyes two different images like a 3D movie or a stereopticon. However, researchers from Australia and China are hoping to change that. They’ve developed a nano-hologram (their term) that is about 1000 times thinner than a human hair. You can see a video about the invention, below.

Conventional holograms modulate the phase of light to give the illusion of three-dimensional depth. But to generate the required phase shifts, those holograms need to be as thick as the optical wavelengths involved. The researchers claim the holograms are “simple” to make, but that depends on what you compare it to. You need some exotic materials, vacuum deposition gear, and a laser that can do femtosecond-long pulses.

The research team has broken this thickness limit with a 25 nanometer hologram. Their technique relies on a topological insulator material a novel quantum material that holds a low refractive index in the surface layer but a much higher refractive index in the bulk of the material. This forms an intrinsic optical resonant cavity which can enhance the phase shifts and makes holography possible.

The next step is to develop a rigid thin film to overlay an LCD screen. The current version has pixels at least ten times too large to be practical for that application, so that’s another hurdle to overcome.

We’ve seen screens that shoot 3D images on movies like Star Wars for years. This isn’t it yet, but it is the next step. Imagine a phone, a wrist watch, or a contact lens that could generate a holographic image. Or a garbage-can-sized robot.

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Digitize Your Room With LIDAR

May 15, 2017 by 20 Comments

What’s the best way to image a room? A picture? Hah — don’t be so old-fashioned! You want a LIDAR rig to scan the space and reconstruct it as a 3D point map in your computer.

Hot on the heels of [Saulius Lukse]’s scanning thermometer, he’s replaced the thermal camera on their pan/tilt setup with a time-of-flight (TOF) camera — a Garmin LIDAR — capable of 500 samples per second and end up scanning their room in a mere fifteen minutes. Position data is combined with the ranging information to produce a point cloud using Python. Open that file in a 3D manipulation program and you’ll be treated to a sight like this:

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Laser Surgery: Expanding The Bed Of A Cheap Chinese Laser Cutter

April 24, 2017 by 29 Comments

Don’t you just hate it when you spend less than $400 on a 40-watt laser cutter and it turns out to have a work area the size of a sheet of copy paper? [Kostas Filosofou] sure did, but rather than stick with that limited work envelope, he modified his cheap K40 laser cutter so it has almost five times the original space.

The K40 doesn’t make any pretenses — it’s a cheap laser cutter and engraver from China. But with new units going for $344 on eBay now, it’s almost a no-brainer. Even with its limitations, you’re still getting a 40-watt CO2 laser and decent motion control hardware to play with. [Kostas] began the embiggening by removing the high-voltage power supply from its original space-hogging home to the right of the work area. With that living in a new outboard enclosure, a new X-Y gantry of extruded aluminum rails and 3D-printed parts was built, and a better exhaust fan was installed. Custom mirror assemblies were turned, better fans were added to the radiator, and oh yeah — he added a Z-axis to the bed too.

We’re sure [Kostas] ran the tab up a little on this build, but when you’re spending so little to start with, it’s easy to get carried away. Speaking of which, if you feel the need for an even bigger cutter, an enormous 100-watt unit might be more your style.

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Little Laser Light Show Is Cleverly Packaged, Cheap To Build

April 22, 2017 by 9 Comments

We’re suckers for any project that’s nicely packaged, but an added bonus is when most of the components can be sourced cheaply and locally. Such is the case for this little laser light show, housed in electrical boxes from the local home center and built with stuff you probably have in your junk bin.

When we first came across [replayreb]’s write-up and saw that he used hard drives in its construction, we assumed he used head galvanometers to drive the mirrors. As it turns out, he used that approach in an earlier project, but this time around, the hard drive only donated its platters for use as low mass, first surface mirrors. And rather than driving the mirrors with galvos, he chose plain old brushed DC motors. These have the significant advantage of being cheap and a perfect fit for 3/4″ EMT set-screw connectors, designed to connect thin-wall conduit, also known as electromechanical tubing, to electrical boxes and panels. The motors are mounted to the back and side of the box so their axes are 90° from each other, and the mirrors are constrained by small cable ties and set at 45°. The motors are driven directly by the left and right channels of a small audio amp, wiggling enough to create a decent light show from the laser module.

We especially like the fact that these boxes are cheap enough that you can build three with different color lasers. In that case, an obvious next step would be bandpass filters to split the signal into bass, midrange, and treble for that retro-modern light organ effect. Or maybe figuring out what audio signals you’d need to make this box into a laser sky display would be a good idea too.

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Robot Targets Eyeballs, Fires Lasers. OSHA’s Gonna Love This One

April 18, 2017 by 60 Comments

If you even think about hacking with lasers, you’re going to hear about eye safety. “Be careful” they’ll say. “Don’t look into laser with remaining eye” is a joke you’ll not be able to avoid. You’ll hear “Where are your goggles”, and about 1000 other warnings. Don’t get us wrong, laser/eye safety is important. However, the constant warnings can get a bit old — especially when you’re working with a “low power” class 3a laser — you know, the kind with a warning label that says “AVOID DIRECT EYE EXPOSURE” in big black letters on a yellow background.

[Michael Reeves] got fed up, and went a bit nuts. He built a robot specifically to shine a laser into human eyes. No, not a medical robot. This ‘bot lives in a pizza box, is built from servos, duct tape, and [Michael’s] tears. It just shoots lasers at people’s eyes. Needless to say, please, don’t try this at home, or at all.

Designing such a diabolical beast was actually rather simple. The software is written in C#. Frames are captured from an old Logitech webcam, then passed into Emgu CV, which is a .NET wrapper for OpenCV. [Michael] runs a simple face detection algorithm, and uses the results to aim a laser. The laser is mounted on two R/C style servos. An Arduino forms the glue between the servos and the PC.

[Michael] has a great deadpan delivery and it all makes for a great video. Think of him of a younger [Medhi] over at Electroboom.  But we can’t condone this behavior. Properly labeled and characterized red laser pointers have never been shown to cause eye damage. Yet if the laser is out-of-spec or reflects of something that further focuses the beam it is certainly capable of damaging eyesight.

We want [Michael’s] eyesight to remain intact so he can make more videos — he’s entertaining, even if ignoring safety warnings isn’t.

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