Cutting Metals With A Diode Laser?

September 21, 2022 by 34 Comments

Hobbyist-grade laser cutters can be a little restrictive as to the types and thicknesses of materials that they can cut. We’re usually talking about CO2 and diode-based machines here, and if you want to cut non-plastic sheets, you’re usually going to be looking towards natural materials such as leather, fabrics, and thin wood.

But what about metals? It’s a common beginner’s question, often asked with a resigned look, that they already know the answer is going to be a hard “no. ” However, YouTuber [Chad] decided to respond to some comments about the possibility of cutting metal sheets using a high-power diode laser, with a simple experiment to actually determine what the limits actually are.

Using an XTool D1 Pro 20W as a testbed, [Chad] tried a variety of materials including mild steel, stainless, aluminium, and brass sheets at a variety of thicknesses. Steel shim sheets in thicknesses from one to eight-thousandths of an inch appeared to be perfectly cuttable, with an appropriate air assist and speed settings, with thicker sheets needing a good few passes. You can definitely see the effect of excess heat in the workpiece, resulting in some discoloration and noticeable warping, but those issues can be mitigated. Copper and aluminium weren’t touched by the beam at all, likely due to the extra reflectivity, but we do have to wonder if appropriate surface treatments could improve matters.

Obviously, we’ve seen that diode lasers can have an impact on metals, simply smearing a little mustard on the workpiece seems to make marking a snap. Whilst we’re on the subject of diode lasers, you can get a lot of mileage from just strapping such a laser module onto a desktop CNC.

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Take The Tedium Out Of Fabric Cutting, Make The Laser Do It

October 29, 2023 by 8 Comments

Fabric must be cut before it can be turned into something else, and [fiercekittenz] shows how a laser cutter can hit all the right bases to save a lot of time on the process. She demonstrates processing three layers of fabric at once on a CO2 laser cutter, cutting three bags’ worth of material in a scant 1 minute and 29 seconds.

The three layers are a PU (polyurethane) waterproof canvas, a woven liner, and a patterned cotton canvas. The laser does a fantastic job of slicing out perfectly formed pieces in no time, and its precision means minimal waste. The only gotcha is to ensure materials are safe to laser cut. For example, PU-based canvas is acceptable, but PVC-based materials are not. If you want to skip the materials discussion and watch the job, laying the fabric in the machine starts around [3:16] in the video.

[fiercekittenz] acknowledges that her large 100-watt CO2 laser cutter is great but points out that smaller or diode-based laser machines can perfectly cut fabric under the right circumstances. One may have to work in smaller batches, but it doesn’t take 100 watts to do the job. Her large machine, for example, is running at only a fraction of its full power to cut the three layers at once.

One interesting thing is that the heat of the laser somewhat seals the cut edge of the PU waterproof canvas. In the past, we’ve seen defocused lasers used to weld and seal non-woven plastics like those in face masks, a task usually performed by ultrasonic welding. The ability for a laser beam to act as both “scissors” and “glue” in these cases is pretty interesting. You can learn all about using a laser cutter instead of fabric scissors in the video embedded below.

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Mosquito Laser Death Grid Is Just What It Sounds Like

September 22, 2023 by 37 Comments

Mosquitoes suck. Quite literally. [Allen Pan] lives in an area where they’re so thick in the air, regular methods of killing them fail to put a dent in their numbers. Thus, he set about building a solution so dangerous we wouldn’t want to be within a mile when it’s turned on. 

[Allen] was inspired by a TED talk from over a decade ago that involved targeting flying mosquitoes with high-powered scanning lasers. This technology never really came to fruition, and raised many questions about laser safety and effectiveness.

Testing the idea with only two mirrors installed.

This solution keeps the lasers, but goes a slightly different route — two 10-watt lasers bounced between multiple mirrors to create a laser death grid. It goes without saying that 10 watt lasers will blind you near instantly even at great range, and can burn skin and cause all manner of other horrors. Bouncing them around with mirrors and waving them about at mosquitoes is a really poor idea when even incidental exposure can do real harm.

Indeed, the laser is so powerful that it burns holes in the mirrors [Allen] used in early testing. It was around this time that [styropyro] was brought in to help ensure everyone involved got through the project with their eyesight intact.

[Allen]’s crew wears laser safety goggles when operating the horrifying handheld device, which mitigates some risk. The team also quickly notice beams escaping from various directions, due in part to the holes burned in their clothes. Electing to wrap the device in a heatproof blanket to avoid accidentally dazzling any nearby pilots was an obvious idea but turning the device off and destroying it would have been smarter.

Sadly, despite looking like the coolest cyberpunk weapon we’ve seen in years, the device doesn’t even kill mosquitoes very effectively. The bugs largely avoided the device, and only a few that flew directly into a beam ended up being cooked. The whole time watching the video, we feared someone dropping the rig, leading to a 10-watt beam bouncing off and striking some poor innocent bystander.

Powerful lasers are cool and useful things. Try and use them responsibly.

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Stack of Si3N4-LiNbO3 forming the integrated laser and integrated into test setup (d). (Credit: Snigirev et al., 2023)

Fast Adjustable Lasers Using Lithium Niobate Integrated Photonics

August 4, 2023 by 14 Comments

Making lasers smaller and more capable of rapidly alternating between frequencies, while remaining within a narrow band, is an essential part of bringing down the cost of technologies such as LiDAR and optical communication. Much of the challenge here lies understandably in finding the right materials that enable a laser which incorporates all of these properties.

A heterogeneous Si3N4–LiNbO3 chip as used in the study. (Credit: Snigirev et al., 2023)

Here a recent study by [Viacheslav Snigirev] and colleagues (press release) demonstrates how combining the properties of lithium niobate (LiNbO3) with those of silicon nitride (Si3N4) into a hybrid (Si3N4)–LiNbO3 wafer stack allows for an InP-based laser source to be modulated in the etched photonic circuitry to achieve the desired output properties.

Much of the modulation stability is achieved through laser self-injection locking via the microresonator structures on the hybrid chip. These provide optical back reflection that forces the laser diode to resonate at a specific frequency, providing the frequency lock. What enables the fast frequency tuning is that this is determined by the applied voltage on the microresonator structure via the formed electrodes.

With a LiDAR demonstration in the paper that uses one of these hybrid circuits it is demonstrated that the direct wafer bonding approach works well, and a number of optimization suggestions are provided. As with all of these studies, they build upon years of previous research as problems are found and solutions suggested and tested. It would seem that thin-film LiNbO3 structures are now finding some very useful applications in photonics.

(Heading image: Stack of Si3N4-LiNbO3 forming the integrated laser and integrated into test setup (d). (Credit: Snigirev et al., 2023) )

A Shutter Speed Tester With Frickin’ Lasers!

July 7, 2023 by 12 Comments

Buying old cameras is one of the best ways yet found to part a geek from their money, but if you don’t mind finding a few duds along the way it’s still possible to pick up something nice without paying the excessive scene tax of an Etsy seller or an online store. The trouble is, in the many decades during which your purchase went from being pride and joy to forgotten in a drawer to lying on the shelf of a thrift store, its performance may have degraded a little. Does the shutter still operate as it should? How long is a split second anyway? You need a shutter speed tester, and luckily for us, [Stuart Brown] has one.

There are no sharks involved in this build, but it does rely on laser diodes as a light source. There are three of them as well as three sensors, packaged photodiodes with a Schmidt trigger. These feed an Arduino which is hooked up to a TFT display, and the software measures how long each diode receives the light. We’re told it can also measure the raise time on curtain shutters, another important metric.

There’s little in the way of usage examples, but we’re guessing it requires positioning the camera between lasers and photodiodes. We’re curious as to how such an instrument would perform on a camera with a fixed lens, or whether it’s only suitable for those with access to the shutter itself. If this subject interests you, it’s not the first shutter speed tester we’ve shown you.

Header image: Runner1616, CC BY-SA 4.0.

Modern CO2 Laser Reviewed

May 15, 2023 by 14 Comments

If you’ve got a laser cutter, it is highly probable that it uses a laser diode. But more expensive machines use a carbon dioxide laser tube along with mirrors. There was a time when these lasers came in two flavors: very expensive and amazing or moderately expensive and cheaply made. However, we are seeing that even the moderately expensive machines are now becoming quite advanced. [Chad] reviews a 55-watt xTool P2. At around $5,000, it is still a little spendy for a home shop, but it does have pretty amazing features. We can only hope some less expensive diode lasers will adopt some of these features.

[Chad’s] video that you can see below attempts to recreate some of the amazing things xTool did on their product introduction live stream. He was able to recreate most, but not all of the results. In some cases, he was also able to do better.

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Laser Projector Built From An Old Hard Drive

May 12, 2023 by 41 Comments

Spinning hard drives are being phased out of most consumer-grade computers in favor of faster technology like solid-state drives and their various interfaces. But there’s still millions of them in circulation that will eventually get pulled from service — so what do we do with them? If you’ve got one that would otherwise be going in the garbage, they can be turned into some other interesting devices like this laser text projector.

Even the slowest drives spin at around 5000 RPM, which is perfect for this type of application. The device works by mounting twelve mirrors, each at a slightly different angle, on a drum which is spun by the drive’s motor. Bouncing a laser off of the spinning drum results in a projection of twelve horizontal lines. By rapidly switching the laser on and off depending on which mirror it’s pointing at, the length of each line can be controlled.

Thanks to persistence of vision, that allows you to show text on the surface that the laser is projected on. At speeds this high, it took [Ben] of Ben Makes Everything quite a few iterations to get it to a usable space. From sensors that were too slow to lasers not bright enough to 3D prints that were not accurate enough, he goes through the design of his build and the process in excellent detail.

After solving all of the problems including building his own constant-current laser power supply, and burning up a few laser diodes in the process, [Ben] has a laser projector capable of displaying readable text at a great distance which is also portable, running on a 12 V power supply. There are some possible areas of improvement that he notes as well, such as an unbalanced 3D printed part causing a bit of a wobble and the Arduino controller not being fast enough for more text. But it’s an impressive project nonetheless, similar to a two-mirror version we saw some time ago but with the ability to display text as well.

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