Turn Your Laser Cutter Into An SLS 3D Printer

February 23, 2016 by 18 Comments

Filament style 3D printers are great, but typically are rather size limited. Laser sintering printers offer huge print beds, but also come with quarter million dollar price tags. What are we supposed to do? Well, thanks to OpenSLS, it might just be possible to turn your laser cutter into your very own SLS 3D printer.

We’ve covered OpenSLS a few times before, but it looks like it’s finally becoming a more polished (and usable) solution. A research article was just recently published on the Open-Source Selective Laser Sintering (OpenSLS0 of Nylon and Biocompatible Polycaprolactone (PDF) that goes over the design and construction of a powder handling module that drops right into a laser cutter.

The team has created the hardware to turn a laser cutter with a bed size of 60cm x 90cm into an SLS printer. The beauty? The majority of the hardware is laser cut which means you already have the means to convert your laser cutter into a 3D printer.

The design files are available on their GitHub. Hardware will likely cost you around $2000, which is peanuts compared to the commercial laser sintering printers. There is tons of info in their article — too much for us to cover in a single post. If you end up building one, please let us know!

Stop Driving Laser Cutters With 3D Printer Software!

January 26, 2016 by 64 Comments

Laser cutters are fantastic pieces of equipment, and thanks to open-source improvements in recent years, are getting even cheaper to make. It can be as simple as throwing a high-powered laser diode onto the head of your 3D printer! With so many home-brew designs out there, wouldn’t it be nice if there was some all-encompassing open-source, laser-cutter controller software? Well, as it turns out — there is, and it’s called LaserWeb.

What started as a simple personal project by [Peter van der Walt] has recently grown into a very formidable piece of software with over 10 contributors in just three months. It even supports four different firmwares, from grbl, to smoothieware, marlin and even lasaurgrbl!

It’s designed to support home-made laser cutters, diode based laser engravers, and even converted Chinese laser cutters. With built-in CAM for PolyLine DXF, and SVG, it can even create rasters from images. Stick around after the break to see a quick video demo — we’re going to have to try this out!

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Wii-Motified Laser Cutter Refocuses For Contoured Cutting

November 1, 2015 by 11 Comments

Still laser cutting all of your parts in 2D? Not the folks over at [Just Add Sharks]. With a few lines of code and an in-tact Wii-Mote, they’ve managed to rig their laser cutter to dynamically refocus based on the height of the material.

The hack is cleanly executed by placing the Wii-Mote both at a known fixed distance-and-angle and within line-of-sight of the focused beam. Thankfully, the image-processing is already done onboard by the Wii-Mote’s image sensor, which simply returns the (x,y) coordinates of the four brightest IR points in view. As the beam moves over the material, the dot moves up or down in the camera’s field-of-view, triggering a refocus of the laser as it cuts. Given that the z-axis table needs to readjust with the contour, the folks at [Just Add Sharks] have slowed down the cutting speed. Finally, it’s worth noting that the Wii-Mote was designed to detect IR LEDs, not a 10600-nanometer laser beam, but we suspect that the Wii-Mote is receiving colors produced by the fluorescing material itself, not the beam. Nevertheless, the result is exactly the same–a dynamically refocusing laser!

Now that [Glowforge] has released a continuously-refocusing laser cutter implemented with stereoscopic cameras, it’s great to see the community following in their footsteps with a DIY endeavor. See the whole system in action after the break!

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Smart Phone Camera Turns Laser Cutter Into Hi-Res Scanner

September 9, 2015 by 35 Comments

Getting decent macro photos always seems to be a chore. Some important detail always seems to be just outside of the depth of field, or you have to be zoomed in so close that you get great detail in one spot but miss the big picture. [Nate B] had such a problem while trying to document some PC boards, and he came up with a nifty hack that uses a laser cutter and a smart phone camera to do the job.

Pv150a-front
Click for detail.

Having first tried scanning the boards with a flat-bed scanner but finding the depth of field unsatisfactory, [Nate B] then went on to his Samsung phone’s camera. Set to panorama mode, he manually scanned across the boards and let the camera stitch the images together. The results were better, but the wobblies got the better of him and the images showed it. He then decided to use a laser cutter — with the laser disabled, of course — as an impromptu X-Y stage to raster his camera above the boards. In a slightly cringe-worthy move, he gingerly clamped the phone to the cutter gantry, started the panorama, and let the cutter move over the board. This results in a rock-solid pictures of his boards with a lot of detail – perfect for his documentation. As a bonus, the honeycomb laser cutter bed makes for an interesting background texture.

Obviously anything could be used to raster a camera and achieve similar results, but full points here for maximizing available resources and not over-complicating a simple job. Yet another reason you can use to justify that laser-cutter purchase.

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How To Build Anything Using Delrin And A Laser Cutter

September 3, 2015 by 58 Comments

Need a simple fab process to go from a humble vector graphic to a final part — in a matter of minutes? The CO2  laser cutter might be the right choice. As these tools open themselves up to widespread use through hackerspaces, I decided to give Delrin some well-deserved time under the spotlight.

The laser cutter yet-again proves itself a formidable tool with the construction of GameCube-Bot V2

This guide is a brief collection of tips and techniques that I’ve either learned from others or discovered on my own over the last couple years working with laser-cut Delrin (a.k.a Acetal) for functional prototypes. I hope this guide serves you well as we keep exploring the limits of the material.

As a disclaimer, keep in mind that in no way are these techniques unique or limited to Delrin. Many are not only years old but also common practice in either engineering design or the local machine shop. This article simply highlights the techniques shown here that perform both repeatably and predictably with Delrin and a couple hand-tools, and I hope to share them with a growing audience of laser cutter enthusiasts.

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3D Objects From A Laser Cutter

September 2, 2015 by 8 Comments

Actors want to be singers and singers want to be actors. The hacker equivalent to this might be that 3D printers want to be laser cutters or CNC machines and laser cutters want to be 3D printers. When [Kurt] and [Lawrence] discovered their tech shop acquired a 120 Watt Epilog Fusion laser cutter, they started thinking if they could coax it into cutting out 3D shapes. That question led them to several experiments that were ultimately successful.

The idea was to cut away material, rotate the work piece, and cut some more in a similar way to how some laser cutters handle engraving cylindrical objects. Unlike 3D printing which is additive, this process is subtractive like a traditional machining process. The developers used wood as the base material. They wanted to use acrylic, but found that the cut away pieces tended to stick, so they continued using wood. However, the wood tends to char as it is cut.

In the end, they not only had to build special jigs and electronics, they also had to port some third party control software to solve some issues with the Epilog Fusion cutter’s built in software. The final refinement was to use the laser’s raster mode to draw surface detail on the part.

The results were better than you’d expect, and fairly distinctive looking. We’ve covered a similar process that made small chess pieces out of acrylic using two passes. This seems like a natural extension of the same idea. Of course, there are very complicated industrial machines that laser cut in three dimensions (see the video below), but they are not in the same category as the typical desktop cutter.

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Using A Laser Cutter To Decap ICs

August 24, 2015 by 26 Comments

The black blob IC is of a particular annoyance to the modern hacker. There is no harm in peeking under the hood to see how the IC works. But when it’s covered in a mountain of seemingly indestructible epoxy, this can be a bit difficult. And such was the case for [Jamie], who had found an old electronic pocket dictionary whose main PC board boasted not one, but two of the black blob ICs.

ICThe lack of traces between the two pushed [Jamie’s] curiosity past the tipping point. He didn’t have access to any nitric acid which is used in the customary chemical decapping process. He did, however, have access to a laser cutter. It turns out that decapping ICs with a laser cutter is not only possible, it’s not that difficult.

100% power at 300mm per seconds on a cheap 40 Watt “eBay” laser cutter is all it takes. Three passes did the trick for [Jamie], but this will be dependent on the thickness of the black blob epoxy. Each case will likely be unique.

Got a laser cutter? Then take a peek at a few black blob ICs and let us know what you find.

Thanks to [ex-parrot] for the tip!