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.

Two chillers side-by-side - the fake chiller on the left and the water fountain chiller (lid-less) on the right

Gutting And Upgrading Laser “Chiller” With No Chill

October 29, 2022 by 10 Comments

Getting a cheap CO2 laser cutter is great for your workshop needs, and while you might get a weaker-than-declared laser tube, it’s still going to cut whatever you need to be cut. That might not be the case for the cooling equipment you’re getting alongside it, however, as [RealTimeKodi] shows in a post-project blogpost. They bought a CX3000 “chiller” and found out it had no chiller components (Nitter), only equipped with a radiator, a fan, and a pump.

Having your laser tube water be somewhat close to ambient temperature is something you can already achieve with an aquarium pump and a bucket of water — and it isn’t worth paying $100 for. Left with the sunk cost and an unfulfilled need for a proper chiller, [RealTimeKodi] started looking for paths to take – first one was using TEC elements. The upgrade process was fun, but the result was subpar, as the elements gobbled power with hardly any useful output to show for it.

[RealTimeKodi] didn’t give up, and eventually found an old water fountain chiller with chiller-like components inside, sold for $200. They could’ve used the water fountain as-is, but a few design issues and thirst for adventure got in the way, indisputably forcing them to stuff the fountain’s guts into the CX3000’s case.

Buying a laser cutter can sometimes feel like buying a 3D printer a decade ago — you get a K40, learn to use it, add the missing safety features, mod in autofocus, upgrade the control board, expand the work surface… That said, our experience shows that you don’t need any of those if A4-sized 3 mm wood cutting suit you, but a proper chiller is still worth its weight in gold-plated acrylic.

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Making A Tape Echo The Traditional Way

September 14, 2022 by 12 Comments

[Juan Nicola] has taken inspiration from the musician hackers of old and re-purposed a reel-to-reel tape recorder into a tape-echo for his guitar with a built-in valve amplifier (video in Spanish).

The principle is to record the sound of the guitar onto a piece of moving magnetic tape, then to read it back again a short time later.  This signal is mixed with the live input and re-recorded back onto the tape further back.  The effect is heard as an echo, and this approach was very popular before digital effects became readily available.

[Juan] installed a new read-head onto his Grundig TK40 and managed to find a suitable mechanical arrangement to keep it all in place.  He has since updated the project by moving to a tape loop, allowing an infinite play-time by re-using the same piece of tape over and over.

Turning tape machines into echo effects is not a new idea, and we’ve shown a few of them over the years, but every one is slightly different!

Both versions are shown after the break.  YouTube closed-caption auto-translate might come in handy here for non-Spanish speakers.

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A portable computer built inside a rugged carrying case

2022 Cyberdeck Contest: The Black Beast Will Help You Survive A Robot Apocalypse

September 4, 2022 by 18 Comments

With AI systems getting smarter every day, one might wonder if they might someday evolve into a sentient Skynet-like system and try to take over the world. We’re not sure how close we are to such a situation, but we do know that if the robot apocalypse were to happen, we would want to stay close to [LordOfAllThings], who would likely be carrying the Black Beast. This scary-sounding machine is in essence a Raspberry Pi-based portable computer built inside an outdoor carrying case, with a wide range of unusual peripherals that make it the digital equivalent of a Swiss army knife. In other words, it’s a cyberdeck built for end times — and whatever comes after.

For example, an array of ESP32-based modules plus an SDR module allow you to intercept and analyze hostile robots’ communications, whether they’re using Bluetooth, WiFi, LoRaWAN, or anything in the 433 or 868 MHz ranges. An FM transmitter comes in handy for reaching out to fellow citizens who are trapped with nothing more than an analog radio receiver, while a suite of environmental sensors (including a Geiger counter) should help determine if Skynet has released any harmful substances to flush out those last few pesky humans. (Ed. note: No marigolds in the promised land and all that.)

If you manage to find a wired Ethernet connection somewhere, a built-in five-port gigabit router lets you set up a local network, obviously with a custom network analyzer to detect any unwanted intrusions. A storage compartment contains every kind of cable you could need, as well as useful gadgets like flashlights and, indeed, an actual Swiss army knife.

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Custom Raspberry Pi Case Shows The Whole Workflow

July 25, 2022 by 29 Comments

If you are a process junkie and love seeing the end-to-end of how a thing is made and with what tools, then watch [Michael Klements] show off his Raspberry Pi case design. His case has quite a few cool-looking elements to it, and incorporates 3D printing as well as laser-cut and clear bent acrylic for a gorgeous three-quarter view.

[Michael]’s write-up (and accompanying video, embedded below) are partly a review of his Creality 3D printer, and partly a showcase of his Raspberry Pi case design (for which he sells the design files for a small fee on his Etsy store.) But the great part is seeing the creation of every piece that goes into the end product. Not everyone is familiar with the way these tools work, or what they can create, so it’s nice to see attention paid to that side of things.

Both the blog post and the video nicely show off what goes into every part. The video opens with unpacking and setting up the 3D printer (skip ahead to 4:58 if you aren’t interested), followed by printing the parts, laser-cutting the acrylic on a K40 laser cutter, bending the acrylic using a small hand tool, and finally, assembling everything. For the curious, there are also links to the exact parts and equipment he uses.

Like we said, it’s part 3D printer review and part showcase of a design he sells, but it’s great to see each of the parts get created, watch the tools get used, and see the results come together in the final product. And should you wish to go in the opposite direction? A one-piece minimalist case for your Raspberry Pi is only a 3D printer away.

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Showing an Ortur lasercutter control module in front of a screen. There's a serial terminal open on the screen, showing the "Ortur Laser Master 3" banner, and then a Grbl prompt.

Watch Out For Lasercutter Manufacturers Violating GPL

July 15, 2022 by 84 Comments

For companies that build equipment like CNC machines or lasercutters, it’s tempting to use open-source software in a lot of areas. After all, it’s stable, featureful, and has typically passed the test of time. But using open-source software is not always without attendant responsibilities. The GPL license requires that all third-party changes shipped to users are themselves open-sourced, with possibility for legal repercussions. But for that, someone has to step up and hold them accountable.

Here, the manufacturer under fire is Ortur. They ship laser engravers that quite obviously use the Grbl firmware, or a modified version thereof, so [Norbert] asked them for the source code. They replied that it was a “business secret”. He even wrote them a second time, and they refused. Step three, then, is making a video about it.

Unfortunately [Norbert] doesn’t have the resources to start international legal enforcement, so instead he suggests we should start talking openly about the manufacturers involved. This makes sense, since such publicity makes it way easier for a lawsuit eventually happen, and we’ve seen real consequences come to Samsung, Creality and Skype, among others.

Many of us have fought with laser cutters burdened by proprietary firmware, and while throwing the original board out is tempting, you do need to invest quite a bit more energy and money working around something that shouldn’t have been a problem. Instead, the manufacturers could do the right, and legal, thing in the first place. We should let them know that we require that of them.

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The laser module shown cutting shapes out of a piece of cardboard that's lying on the CNC's work surface

Giant CNC Partners With Powerful Laser Diode

April 30, 2022 by 13 Comments

[Jeshua Lacock] from 3DTOPO owns a large-format CNC (4’x8′, or 1.2×2.4 m), that he strongly feels is lacking laser-cutting capabilities. The frame is there, and a 150 W CO2 laser tube has been sitting in a box for ages – what else could you need? Sadly, at such a scale, aligning the mirrors is a tough and finicky job – and misalignment can be literally blinding. After reading tales about cutters of such size going out of alignment when someone as much as walked nearby, he dropped the idea – and equipped the CNC head with a high-power laser diode module instead. Having done mirror adjustment on a few CO2 tube-equipped lasers, we can see where he’s coming from.

Typically, the laser modules you see bolted onto CNC heads are firmly under three watts, which is usually only enough for engraving. With a module that provides 5 watts of optical power, [Jeshua] can cut cardboard and thin plywood as well he tells us even 10 W optical power modules are available, just that he didn’t go for one. We reckon that 20 W effective power diodes are not that far into our future, which is getting very close to the potential of the blue box “40 W but actually 35 W but actually way less” K40 laser cutters we cherish. [Jeshua]’s cutter is not breaking speed limits, but it’s built on what’s already there, and the diode is comparatively inexpensive. Equipped with a small honeycomb surface and what seems to be air assist, it’s shown in the video cutting an ornamental piece out of cardboard!

We hackers have been equipping CNCs with laser diodes for a while, but on a way smaller scale and with less powerful diodes – this is definitely a step up! As a hacker, you should have at least some laser cutting options at your disposal, and this overview of CO2 cutters and their availability can get you started. We’ve also given you detailed breakdowns about different sides of laser cutting, be it the must-have of safety, or the nice-to-have of air assist.

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