Amazing 3D-Scanner Teardown and Rebuild

0_10ea1b_776cdc71_origPour yourself a nice hot cup of tea, because [iliasam]’s latest work on a laser rangefinder (in Russian, translated here) is a long and interesting read. The shorter version is that he got his hands on a broken laser security scanner, nearly completely reverse-engineered it, got it working again, put it on a Roomba that was able to map out his apartment, and then re-designed it to become a tripod-mounted, full-room 3D scanner. Wow.

The scanner in question has a spinning mirror and a laser time-of-flight ranger, and is designed to shut down machinery when people enter a “no-go” region. As built, it returns ranges along a horizontal plane — it’s a 2D scanner. The conversion to a 3D scanner meant adding another axis, and to do this with sufficient precision required flipping the rig on its side, salvaging the fantastic bearings from a VHS machine, and driving it all with the surprisingly common A4988 stepper driver and an Arduino. A program on a PC reads in the data, and the stepper moves another 0.36 degrees. The results speak for themselves.

This isn’t [iliasam]’s first laser-rangefinder project, naturally. We’ve previously featured his homemade parallax-based ranger for use on a mobile robot, which is equally impressive. What amazes us most about these builds is the near-professional quality of the results pulled off on a shoestring budget.

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Foldable Dymaxion Globe

Some time back, we posted about [Gavin]’s laser-cut/3D printed Dymaxion Globe — if you haven’t read about it yet, you should check it out. [noniq] loved the idea, and like a true hacker, built and shared an improved Foldable Dymaxion Globe. It can snap together to form an icosahedron globe, or it can be laid flat to form a map.

Duct tape, stoppers and magnet holders
Duct tape, stoppers and magnet holders

Like the original, [noniq]’s version is laser cut and engraved, and uses some 3D printed parts. But it does away with the fasteners (that’s 60 pairs of nuts and bolts), and instead uses neodymium magnets to make all the triangle pieces snap together to form the icosahedron globe. The hinges are simply some pieces of gaffer-tape.

This design improvement creates a cleaner globe and also addresses some of the concerns posted in the comments of the earlier build. The design files are available for download on [noniq]’s blog — you need to 3D print some magnet holders and stopper plates, and laser cut the 20 triangle tiles. The stopper plates help ensure that the angle between tiles when it is put together is limited to 138 degrees, making it easier to assemble the globe.

Check out the video after the break to hear the satisfying “thunk” of neodymium magnets snapping together.

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Convert that Cheap Laser Engraver to 100% Open-Source Toolchain

laserweb-on-cheap-laser-squareLaserWeb is open-source laser cutter and engraver software, and [JordsWoodShop] made a video tutorial (embedded below) on how to convert a cheap laser engraver to use it. The laser engraver used in the video is one of those economical acrylic-and-extruded-rail setups with a solid state laser emitter available from a variety of Chinese sellers (protective eyewear and any sort of ventilation or shielding conspicuously not included) but LaserWeb can work with just about any hardware, larger CO2 lasers included.

LaserWeb is important because most laser engravers and cutters have proprietary software. The smaller engravers like the one pictured above use a variety of things, and people experienced with larger CO2 laser cutters may be familiar with a piece of software called LaserCut — a combination CAD program and laser control that is serviceable, but closed (my copy even requires a USB security dongle, eww.)

LaserWeb allows laser engravers and cutters to be more like what most of us expect from our tools: a fully open-source toolchain. For example, to start using LaserWeb on one of those affordable 40 W blue-box Chinese laser cutters the only real hardware change needed is to replace the motion controller with an open source controller like a SmoothieBoard. The rest is just setting up the software and enjoying the added features.

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Laser Cutting a Wooden Dymaxion Globe

Everyone knows that globes are cool — what else would you use as the centerpiece of your library/study? But, sadly, making your own isn’t a simple process. Even if you had a large (preferably hollow) sphere to work with, you’d still have to devise a clever way of printing the map in sections that can be glued to the curved surface. Wouldn’t it be easier if you could just laser cut flat sections, and assemble them to form a faceted “globe?”

Well, it is, and you can! Because, [Gavin] over at (a Hackaday favorite) has created the files to do just that! This map projection, originally designed by the very interesting Buckminster Fuller, is designed to be either laid flat or three-dimensionally on an icosahedron (a 20-sided polyhedron). That makes it perfect for laser cutting, as each of the 20 faces can be cut from flat stock.


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Sintering Sand WIth A Laser Cutter

We are all used to Fused Deposition Modeling, or FDM, 3D printers. A nozzle squirts molten material under the control of a computer to make 3D objects. And even if they’re usually rather expensive we’re used to seeing printers that use Stereolithography (SLA), in which a light-catalysed liquid monomer is exposed layer-by layer to allow a 3D object to be drawn out. The real objects of desire though are unlikely to grace the average hackspace. Selective Laser Sintering 3D printers use a laser on a bed of powder to solidify a 3D object layer by layer.

The laser creating a ring.
The laser creating a ring.

While an SLS printer may be a little beyond most budgets, it turns out that it’s not impossible to experiment with the technology. [William Osman] has an 80 W laser cutter, and he’s been experimenting with it sintering beach sand to create 2D objects. His write-up gives a basic introduction to glassmaking and shows the difference between using sand alone, and using sodium carbonate to reduce the melting point. He produces a few brittle barely sintered tests without it, then an array of shapes including a Flying Spaghetti Monster with it.

The results are more decorative than useful at the moment, however it is entirely possible that the technique could be refined. After all, this is beach sand rather than a carefully selected material, and it is quite possible that a finer and more uniform sand could give better results. He says that he’ll be investigating its use for 3D work in the future.

We’ve put his video of the whole process below the break, complete with worrying faults in home-made laser wiring. It’s worth a watch.

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Breathe Easy with a Laser Cutter Air Filter

A laser cutter is a great tool to have in the shop, but like other CNC machines it can make a lousy neighbor. Vaporizing your stock means you end up breathing stuff you might rather not. If you’re going to be around these fumes all day, you’ll want good fume extraction, and you might just consider a DIY fume and particulate filter to polish the exhausted air.

15203365_644939182347358_619032134291602214_nWhile there’s no build log per se, [ZbLab]’s Facebook page has a gallery of photos that show the design and build in enough detail to get the gist. The main element of the filter is 25 kg of activated charcoal to trap the volatile organic compounds in the laser exhaust. The charcoal is packed into an IKEA garbage can around a prefilter made from a canister-style automotive air cleaner – [ZbLab] uses a Filtron filter that crosses to the more commonly available Fram CA3281. Another air cleaner element (Fram CA3333) makes sure no loose charcoal dust is expelled from the filter. The frame is built of birch ply and the plumbing is simple PVC. With a 125mm inlet it looks like this filter can really breathe, and it would easily scale up or down in size according to your needs.

No laser cutter in your shop to justify this filter, you say? Why not build one? Or, if you do any soldering, this downdraft fume extractor is a good way to clear the air.

Drop-in Laser Cutter Alignment Beam Works like a Charm

Every laser cutter enthusiast eventually pops the question: how on earth do I align an invisible beam that’s more-than-happy to zap my eyeballs, not to mention torch everything else in its path? We hate to admit it, but laser cutter beam alignment is no easy task. To greatly assist in this endeavor, though, some folks tend to mix a red diode laser into the path of the beam. Others temporarily fixture that diode laser directly in the beam path and then remove it once aligned.

One deviant has taken diode laser mixing to the next level! [Travis Reese] has added a servo-driven diode laser that dynamically drops into the path of the laser tube when the lid pops up, and then tilts comfortably out of the laser path when the lid closes again.
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