Laser Cut-and-Weld Makes 3D Objects

Everybody likes 3D printing, right? But it’s slow compared to 2D laser cutting. If only there were a way to combine multiple 2D slices into a 3D model. OK, we know that you’re already doing it by hand with glue and/or joints. But where’s the fun in that?

LaserStacker automates the whole procedure for you. They’ve tweaked their laser cutter settings to allow not just cutting but also welding of acrylic. This lets them build up 3D objects out of acrylic slices with no human intervention by first making a cutting pass at one depth and then selectively re-welding together at another. And they’ve also built up some software, along with a library of functional elements, that makes designing these sort of parts easier.

There’s hardly any detail on their website about how it works, so you’ll have to watch the video below the break and make some educated guesses. It looks like they raise the cutter head upwards to make the welding passes, probably spreading the beam out a bit. Do they also run it at lower power, or slower? We demand details!

Anyway, check out the demo video at 3:30 where they run through the slice-to-depth and heal modes through their paces. It’s pretty impressive.

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Full-Color Edge-Lit Laser Cut Acrylic

Edge-lit art has been around for a very long time, and most people have probably come across it in a gift shop somewhere. All it takes is a pane of transparent material (usually an acrylic sheet) with the artwork etched into the surface. Shine a light into the sheet from the edge, and refraction takes over to light up the artwork. However, this technique is almost always limited to a single pane, and therefore a single color. [haqnmaq] wanted to take this idea and make it full-color, and has written up a great Instructables tutorial on how to accomplish this.

If you want to make something like this yourself, the only thing you really need is a laser cutter and some basic electronics equipment. The process itself is so straightforward that it’s surprising that it isn’t more common. You start by taking a photo of your choice and use an image editor to break it up into three photos, one for red, one for green, and one for blue. Each of those photos is then etched into an acrylic pane with a laser cutter. When the panes are positioned in front of each other and edge-lit with their respective LEDs, a full-color image comes to life.

This isn’t the first edge-lit artwork project we’ve featured, but it definitely has the highest fidelity. Because [haqnmaq’s] technique uses three colors, you can use his tutorial to reproduce any photo you like. You could even take this a step further and create animated photos by adding more panes and lighting them up in the correct sequence!

“Arduino Borealis” Combines LEDs and Paint

[Stef Cohen] decided to combine three different artistic mediums for her latest project. Those are painting, electronics, and software. The end goal was to recreate the aurora borealis, also known as the northern lights, in a painting.

The first step was to make the painting. [Stef] began with a shadow box. A shadow box is sort of like a picture frame that is extra deep. A snowy scene was painted directly onto the front side of the glass plate of the shadow box using acrylic paint. [Stef] painted the white, snowy ground along with some pine trees. The sky was left unpainted, in order to allow light to shine through from inside of the shadow box. A sheet of vellum paper was fixed to the inside of the glass pane. This serves to diffuse the light from the LEDs that would eventually be placed inside the box.

Next it was time to install the electronics. [Stef] used an off-the-shelf RGB LED matrix from Adafruit. The matrix is configured with 16 rows of 32 LEDs each. This was controlled with an Arduino Uno. The LED matrix was mounted inside the shadow box, behind the vellum paper. The Arduino code was easily written using Adafruit’s RGB Matrix Panel library.

To get the aurora effect just right, [Stef] used a clever trick. She took real world photographs of the aurora and pixelated them using Photoshop. She could then sample the color of each pixel to ensure that each LED was the appropriate color. Various functions from the Adafruit library were used to digitally paint the aurora into the LED matrix. Some subtle animations were also included to give it an extra kick.

Beest of an RC Toy

Sometimes hackers and makers hack and make stuff just because they can. Why spend hours in a CAD program designing a gazillion gears, brackets and struts? Why cut them all out on a homemade CNC? Why use a PIC and perf board to control everything? Because we can. Well, because [Est] can, rather. He put together this RC controlled beast of a toy with multiple legs and crushing claws.

It’s made out of 6 mm acrylic and threaded rod. The legs are controlled by two DC motors, while the mouth uses two geared steppers. The beast talks to the controller via a pair of 433 MHz transceivers using a protocol similar to how an IR remote talks to a television. A handful of LEDs lights up the clear acrylic, making it look extra scary.

This design is, of course, based on the Strandbeest concept from [Theo Jansen]. It’s a great robotics project because your project doesn’t suffer under its own weight. It’s more like a tracked machine. In fact, we saw a huge rideable version made of metal at BAMF this year. That’s one you just can’t miss!

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Linear Book Scanner Does it with Arduino

About two and half years ago, the Google Books team open-sourced the plans for their book scanning rig, and there was much rejoicing. As [Dany Qumsiyeh] explained in the Google Tech talk we linked to at the time, the scanner uses a vacuum to lift the next page from the stack and turn it, saving hours of human labor and, admittedly, putting books in a little bit of danger.

[Chris] tipped us off about a different take on the linear book scanner created by [Forssa1] that uses server fan to turn the pages. [Forssa1]’s rig is built from laser-cut acrylic and employs two handheld scanners driven by an Arduino Mega. We don’t have a great deal of information about this build, but you can check it out after the break.

UPDATE: [Forssa1] checked in with us and sent a link to more build photos of his book scanner.

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Laser-Cut Clock Kicks Your CAD Tools to the Curb and Opts for Python

In a world deprived of stock hardware other than #6-32 bolts and sheets and sheets of acrylic, [Lawrence Kesteloot] took it upon himself to design and build a laser-cut pendulum clock. No Pricey CAD programs? No Problem. In a world where many fancy CAD tools can auto-generate gear models, [Lawrence] went back to first principles and wrote scripts to autogenerate the gear profiles. Furthermore, not only can these scripts export SVG files for the entire model for easy laser cutting, they can also render a 3D model within the browser using Javascript.

Given the small selection of materials, the entire project is a labor of love. Even the video (after the break) glosses over the careful selection of bearings, bolt-hole spacing, and time-sensitive gear ratios, each of which may be an easy macro in other CAD programs that [Lawrence], in this case, needed to add himself.

Finally, the entire project is open source and up for download on the Githubs. It’s not every day we can build ourselves a pendulum clock with a simple command-line-incantation to

make cut

Thanks for the tip, [Bartgrantham]!

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Laser-Cut Clock Uses Planetary Gear

[wyojustin] was trying to think of projects he could do that would take advantage of some of the fabrication tech that’s become available to the average hobbyist. Even though he doesn’t have any particular interest in clocks, [wyojustin] discovered that he could learn a lot about the tools he has access to by building a clock.

[wyojustin] first made a clock based off of a design by [Brian Wagner] that we featured a while back. The clock uses an idler wheel to move the hour ring so it doesn’t need a separate hour hand. After he built his first design, [wyojustin] realized he could add a planetary gear that could move an hour hand as well. After a bit of trial and error with gear ratios, he landed on a design that worked.

The clock’s movement is a stepper motor that’s driven by an Arduino. Although [wyojustin] isn’t too happy with the appearance of his electronics, the drive setup seems to work pretty well. Check out [wyojustin]’s site to see the other clock builds he’s done (including a version with a second hand), and you can peruse all of his design files on GitHub.

Looking for more clock-building inspiration? Check out some other awesome clock builds we’ve featured before.