CO2 laser cutting ceramic sheet under water film

Water Is The Secret Ingredient When Laser Cutting Ceramics To Make Circuits

October 2, 2021 by 21 Comments

[Ben Krasnow] over at Applied Science was experimenting with cutting inexpensive ceramic sheets with his cheap CO2 laser cutter when he found that (just as expected) the thermal shock of the CO2 beam would cause cracking and breaking of the workpiece. After much experimentation, he stumbled upon a simple solution: submersion under a thin layer of water was sufficient to remove excess heat, keeping thermal shock at bay, and eventually cutting the material. Some prior art was uncovered, which we believe is this PHD thesis (PDF) from Manchester University in the UK. This is a great read for anyone wanting to dig into this technique a little deeper.

The CO2 laser cutter is a very versatile tool, capable of cutting and etching a wide range of materials, many of natural origin, such as cardboard, leather and wood, as well as certain plastics and other synthetic materials. But, there are also materials that are generally a no-go, such as metals, ceramics and anything that does not absorb the laser wavelength adequately or is too reflective, so having another string in one’s bow is a good thing. After all, not everyone has access to a fibre laser.

After dispensing with the problem of how to cut ceramic, it got even more interesting. He proceeded to deposit conductive traces sufficiently robust to solder to. A mask was made from vinyl sheet and a squeegee used to deposit a thick layer of silver and glass particles 1 um or less in size. This was then sintered in a small kiln, which was controlled with a Raspberry Pi running PicoReFlow, and after a little bit of scrubbing, the surface resistance was a very usable 2 mΩ/square. Holes cut with the laser, together with some silver material being pushed through with the squeegee formed through holes with no additional effort. That’s pretty neat!

Some solder paste and parts were added to the demo board, and with an added flare for no real reason other than he could, reflowed by simply applying power direct to the board. A heater trace had been applied to the bottom surface, rendering the board capable of self-reflowing. Now that is cool!

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Microwave Ovens: Need More Power? Use Lasers Instead!

September 28, 2021 by 15 Comments

You know how it is, you get in late from work, you’ve been stuck in traffic for what seems like an eternity, and you’re hungry. You reach for the microwave meal, and think, if only I didn’t have to wait that three-and-a-half minutes, 900 watts just isn’t enough power. What you need is a laser microwave, and as luck would have it, [Styropyro] has built one, so you don’t have to. No, really, don’t.

After he observed a microwave only operating on a half-wave basis, and delivering power 50% of the time, he attempted to convert it to full-wave by doubling up the high voltage transformer and rectification diodes. While this worked, the poor suffering magnetron didn’t go the full mile, and died somewhat prematurely.

Not to be disheartened, the obvious thing was to ditch the whole concept of cooking with boring old radio waves, and just use a pile of frickin’ lasers instead. Now we’re not sure how he manages to get hold of some of the parts he uses, and the laser array modules look sketchy to say the least, and to be frank, we don’t think they should be easy to get given the ridiculous beam power they can muster.

With the build completed to the usual [Styropryo] level of excellent build quality, he goes on to produce some mouthwatering delicacies such as laser-charred poptart, incinerated steak with not-really-caramelised onions and our favourite laser-popcorn. OK, he admits the beam has way too much power, really should be infrared, and way more diffuse to be even vaguely practical, but we don’t care about practicality round these parts. Who wouldn’t want the excitement of going instantly blind by merely walking into the kitchen at the wrong time?

We’ve covered a fair few microwave oven related hacks before, including a neat microwave kiln, and hacks using microwave parts, such as a janky Jacob’s ladder, but this is probably the first laser microwave we’ve come across. Hopefully the last :)

And remember kids, as [Styropyro] says in pretty much every video on his channel:

All the crazy stuff I’m about to do was done for educational purposes, in fact if you were to try any of this stuff at home, you’d probably die…

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Lasers used to detect handprint.

DIY Laser Speckle Imaging Uncovers Hidden Details

September 17, 2021 by 31 Comments

It sure sounds like “laser speckle imaging” is the sort of thing you’d need grant money to experiment with, but as [anfractuosity] recently demonstrated, you can get some very impressive results with a relatively simple hardware setup and some common open source software packages. In fact, you might already have all the components required to pull this off in your own workshop right now and just not know it.

Anyone who’s ever played with a laser pointer is familiar with the sparkle effect observed when the beam shines on certain objects. That’s laser speckle, and it’s created by the beam reflecting off of microscopic variations in the surface texture and producing optical interference. While this phenomenon largely prevents laser beams from being effective direct lighting sources, it can be used as a way to measure extremely minute perturbations in what would appear to be an otherwise flat surface.

In this demonstration, [anfractuosity] has combined a simple red laser pointer with a microscope’s 25X objective lens to produce a wider and less intense beam. When this diffused beam is cast onto a wall, the speckle pattern generated by the surface texture can plainly be seen. What’s not obvious to the naked eye is that touching the wall with your hand actually produces a change in the speckle pattern. But if you take high-resolution before and after shots, the images can be run through OpenCV to highlight the differences and reveal a ghostly hand-print.

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Harp Uses Frikin’ Lasers

September 14, 2021 by 12 Comments

We aren’t sure if you really need lasers to build [HoPE’s] laser harp. It is little more than some photocells and has an Arduino generate tones based on the signals. Still, you need to excite the photocells somehow, and lasers are cheap enough these days.

Mechanically, the device is a pretty large wooden structure. There are six lasers aligned to six light sensors. Each sensor is read by an analog input pin on an Arduino armed with a music-generation shield. We’ve seen plenty of these in the past, but the simplicity of this one is engaging.

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Squares of sample materials placed on the laser bed awaiting the sensing head

Smart Laser Cutter Ad-on Detects Material Optically

September 6, 2021 by 9 Comments

Come on now, admit it. You’ve done it. We’ve done it. You know — you were really sure that sheet of plastic stock you found lying around the hackerspace was acrylic right? You dialled in the settings, loaded the design, set the focus and pushed the little green ‘start’ button. Lots of black smoke, fire, and general badness ensued as you lunged for the red ‘stop’ button, before lifting the lid to work out how you’re going to clean this one up.

That was not acrylic. That was polycarbonate.

What you need is the latest gadget from MIT: SensiCut: A smart laser cutter system that detects different materials automatically.

The technique makes use of so-called ‘speckle imaging’ where a material illuminated by a laser will produce a unique pattern of reflected spots, or speckles into a camera. By training a deep neural model with a large set of samples, it was found possible to detect up to 30 types of material with 98% accuracy.

The pre-baked model runs on a Raspberry PI zero with an off-the-shelf camera all powered from a power bank. This allows the whole assembly to simply drop onto an existing laser cutter head, with no wiring needed.

Even if you’re a seasoned laser cutter user, with a well-controlled stock pile, the peace-of-mind this could give would definitely be worth the effort. A more detailed description and more videos may be found by reading the full paper. Here’s hoping they release the system as open source, one day in the not-to-distant future. If not, then, you know what to do :)

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Small Footprint Scara Laser Engraver Has Massive Build Area

August 31, 2021 by 22 Comments

One of the limitations of the conventional Cartesian CNC platforms is that the working area will usually be smaller than its footprint. SCARA arms are one of the options to get around this, as demonstrated by [How To Mechatronics], with his SCARA laser engraver.

This robot arm is modified from the original build we featured a while back, which had a gripper mounted. It uses mainly standard 3D printer components with 3D printed frame parts. The arms lengths are sized to fold over the base and take up little table horizontal space when not in use. It can work in a large semi-circular area around itself, and if a proper locating and homing method is implemented, it can be moved around and engrave a large area section by section.

One of the challenges of SCARA arms is rigidity. As the cantilevered arm extends, it tends to lean over under its weight. In [How To Mechatronics]’s case, it showed up as skewed engravings, which he managed to mitigate to some degree in the Marlin firmware.

Another possible solution is to reduce the weight of the arms by moving the motors to the base, as was done with the Pybot or dual-arm SCARA printers like the RepRap Morgan.

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Interactive Musical Art Installation Mixes Vintage, Modern, Lasers, And…Bubbles? Bubbles.

August 21, 2021 by 3 Comments

Acorn BBC Master. Apple IIe. Ampex 270 Terminal. Vectrex game console. You’d be hard pressed to find a more diverse hardware collection in the average hacker’s lab. When you add seven Raspberry Pi’s, five CRT monitors, an analog oscilloscope and an LED wall to the mix, one starts to wonder at the menagerie of current and retro hardware. What kind of connoisseur would have such a miscellaneous collection? That’s when you spot smoke and fog machines sitting next to an RGB Laser.

Finally, you learn that all of this disparate paraphernalia is networked together. It is then that you realize that you’re not just dealing with a multi-talented hacker- you’re dealing with a meticulous maestro who’s spent lockdown finishing a project he started nearly twenty years ago!

AUVERN comes alive in a show of light and sound whenever someone enters its view.
AUVERN comes alive in a show of light and sound whenever someone enters its view.

The machine is called AUVERN and it’s the product of the creative mind of [Owen]. Taking advantage of advances in technology (and copious amounts of free time), [Owen] laboriously put his collection of older rigs to work.

A Python script uses a Kinect sensor’s input to control a Mac Mini running Digital Audio Workstation software. The operator’s location, poses and movements are used to alter the music, lights, and multimedia experience as a whole. MIDI, Ethernet, and serial communications tie the hardware together through Raspberry Pi’s, vintage MIDI interfaces, and more. Watch the video below the break for the technical explanation, but don’t miss the videos on [Owen]’s website for a mesmerizing demonstration of AUVERN in full swing.

AUVERN makes use of the Vectrex32 upgrade which we have previously covered, and we are unavoidably reminded of another pandemic inspired bubble machine. Don’t forget to send us your hacks, projects, and creations through the Tip Line!

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