Arduino Revives Junkyard Laser Cutter

April 19, 2018 by 30 Comments

Some people have all the luck. [MakerMan] writes in to gloat tell us about a recent trip to the junkyard where he scored a rather serious looking laser cutter. This is no desktop-sized K40 we’re talking about here; it weighs in at just under 800 pounds (350 Kg), and took a crane to deliver the beast to his house. But his luck only took him so far, as closer inspection of the machine revealed it was missing nearly all of its internal components. Still, he had the frame, working motors, and laser optics, which is a lot more than we’ve ever found in the garbage.

After a whirlwind session with his wire cutters, [MakerMan] stripped away most of the existing wiring and the original control board inside the electronics bay. Replacing the original controller is an Arduino Nano running Grbl, likely giving this revived laser cutter better compatibility with popular open source tools than it had originally. Even though the laser cutter was missing a significant amount of hardware, he did luck out that both the motor drivers were still there (and working) as well as the dual power supplies to run everything.

After a successful motion test, [MakerMan] then goes on to install a new 90W laser tube. Supporting the tube is a rigged up water cooling system using a plastic jug and a cheap bilge pump. He also added an air assist system, complete with side mounted compressor. This pushes air over the laser aperture, helping to keep smoke and debris away from the beam. Finally, a blower was installed in the bottom of the machine with flexible ducting leading outside to vent out the smoke and fumes that are produced when the laser is in operation.

This machine is a considerable upgrade from the previous laser [MakerMan] built, and as impressive as this rebuild is so far, we’re interested in seeing where it goes from here. If you ask us, this thing is begging for an embedded LaserWeb server.

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US Military Developing Laser Plasma Speakers

March 24, 2018 by 27 Comments

It probably won’t surprise you to know that the US military is very interested in using lasers as weapons. Directed energy weapons such as lasers have many advantages over more traditional kinetic weaponry, not least of which the fact that you don’t need to cart around ammunition for them. But somewhat surprisingly, some of the most promising laser developments have been in the field of non-lethal weaponry. While the mental image of a laser is usually a destructive one, recent demonstrations by the Joint Non-Lethal Weapons Program show lasers can do more than blow holes your target.

As reported by [Patrick Tucker] of Defense One, a radical new laser-powered sonic weapon was shown off at the “Directed Energy to DC Exhibition”. The system uses two lasers: one to generate a ball of plasma when it hits the target, and another to modulate the plasma ball in open air. The result is a variation of the classic plasma speaker demonstration, where plasma is used as a a driver for a massless speaker.

Currently the system is capable of generating a deafening crack at the target area, with a measured intensity as high as 140 dB. That’s about as loud as fireworks or a shotgun going off at close distance, and in theory is enough to drive off whoever is unlucky enough to be targeted with the beam.

In time, the researchers hope to refine their secondary modulation laser to the point that they can play audio over the plasma. This would allow the beam to be used as a directed loud speaker of sorts, which could prove useful for defensive applications. Only the target would be able to hear the audio, which could be a recording telling them they were entering a secured area. A disembodied voice telling you to turn around sounds like a extremely effective non-violent deterrent to us. The voices in our head don’t have to tell us twice.

We recently looked at the possibility of targeted sonic weapons being used in Cuba, and of course, we’ve covered many plasma speakers on Hackaday over the years. Plasma speakers have always been more or less nothing more than a fun high voltage demonstration, so to see them potentially weaponized is a crossover episode we weren’t expecting.

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What’s Inside A Neonode Laser Sensor?

March 6, 2018 by 16 Comments

Every once in a while, you get your hands on a cool piece of hardware, and of course, it’s your first instinct to open it up and see how it works, right? Maybe see if it can be coaxed into doing just a little bit more than it says on the box? And so it was last Wednesday, when I was at the Embedded World trade fair, and stumbled on a cool touch display floating apparently in mid-air.

The display itself was a sort of focused Pepper’s Ghost illusion, reflected off of an expensive mirror made by Aska3D. I don’t know much more — I didn’t get to bring home one of the fancy glass plates — but it looked pretty good. But this display was interactive: you could touch the floating 2D projection as if it were actually there, and the software would respond. What was doing the touch response in mid-air? I’m a sucker for sensors, so I started asking questions and left with a small box of prototype Neonode zForce AIR sensor sticks to take apart.

The zForce sensors are essentially an array of IR lasers and photodiodes with some lenses that limit their field of view. The IR light hits your finger and bounces back to the photodiodes on the bar. Because the photodiodes have a limited angle over which they respond, they can be used to triangulate the distance of the finger above the display. Scanning quickly among the IR lasers and noting which photodiodes receive a reflection can locate a few fingertips in a 2D space, which explained the interactive part of the floating display. With one of these sensors, you can add a 2D touch surface to anything. It’s like an invisible laser harp that can also sense distance.

The intended purpose is fingertip detection, and that’s what the firmware is good at, but it must also be the case that it could detect the shape of arbitrary (concave) objects within its range, and that was going to be my hack. I got 90% of the way there in one night, thanks to affordable tools and free software that every hardware hacker should have in their toolbox. So read on for the unfortunate destruction of nice hardware, a tour through some useful command-line hardware-hacking tools, and gratuitous creation of animations from sniffed SPI-like data pulled off of some test points.

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Review: NEJE DK-8-KZ Laser Engraver

March 1, 2018 by 100 Comments

When I got my first 3D printer I was excited, but now that I’m contemplating adding a forth to my collection, I have to come to the terms with the fact that these machines have all the novelty of a screwdriver at this point. Which is fine; getting the cost down and availability up is the key to turning a niche piece of technology into a mainstream tool, and the more people with 3D printers at home or in their workshop the better, as far as I’m concerned. But still, there’s a certain thrill in exploring the cutting edge, and I’ve been looking for something new to get excited about as of late.

NEJE DK-8-KZ

Lasers seem like an interesting next step in my quest towards complete in-house fabrication capability, so I started researching cheap setups to get my feet wet. In the course of looking up diode-powered laser cutters, I came across the NEJE DK-8-KZ. At only 1W, there’s no question this device isn’t going to be cutting a whole lot. In fact, it’s specifically sold as an engraver. But given the fact that you can get one of these little guys for around $70 USD shipped, it’s hard to complain.

Now I wasn’t 100% sure what I would do with a laser engraver, but I thought it would be a good way to test the waters before putting serious money (and time) into something more powerful. Plus, if I’m being totally honest, I wanted to start on something on the lower end of the power spectrum because I’m terrified of blinding myself.

So what kind of laser do you get for $70? Let’s find out… Continue reading “Review: NEJE DK-8-KZ Laser Engraver” →

Laser Galvo Control Via Microcontroller’s DAC

February 15, 2018 by 33 Comments

Mirror galvanometers (‘galvos’ for short) are the worky bits in a laser projector; they are capable of twisting a mirror extremely quickly and accurately. With two of them, a laser beam may be steered in X and Y to form patterns. [bdring] had purchased some laser galvos and decided to roll his own control system with the goal of driving the galvos with the DAC (digital to analog) output of a microcontroller. After that, all that was needed to make it draw some shapes was a laser and a 3D printed fixture to hold everything in the right alignment.

The galvos came with drivers to take care of the low-level interfacing, and [bdring]’s job was to make an interface to translate the 0 V – 5 V output range of his microcontroller’s DAC into the 10 V differential range the driver expects. He succeeded, and a brief video of some test patterns is embedded below.

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Teardown: What’s Inside A Christmas Laser Projector?

January 22, 2018 by 55 Comments

In the world of big-box retail, December 26th is a very special day. The Christmas music playing on the overhead speakers switches back to the family friendly Top 40, the store’s decorations get tossed in the compactor, and everything that’s even remotely related to the holiday is put on steep clearance. No more money to be made on the most commercialized of all holidays, so back to business as usual.

It’s in this narrow corridor of time, between the Great Holiday Unloading and the new spring products coming in, that you can find some fantastic deals on Christmas decorations. Not that long ago, this would hardly be exciting news for the readers of Hackaday. But Christmas lights and decorations have really started pushing the envelope in terms of technology: addressable RGB LED strands, Bluetooth controlled effects, and as of the last couple years, friggin’ lasers.

That’s right, you’ve seen them all over the neighborhood, probably took a few stray beams to the eye, you might even own your own. Laser projectors have been one of the most popular Christmas decorations for the last couple of years, and it’s not hard to see why. Just set the projector up in front of your house, and you’re done. No need to get on a ladder and string lights on the roof when you can just blast some directed energy up there instead.

Given how popular they are, I was surprised to see a lone Home Accents Holiday Multi-Color Light Projector on the clearance rack at Home Depot for around $14 a few days after Christmas. This was a 75% price reduction from normal MSRP, and right in that sweet impulse-buy price range. Let’s see what’s hiding inside!

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Improving Cheap Laser Engravers For PCB Fabrication

December 22, 2017 by 24 Comments

A few months ago, [Marco] picked up a cheap, cheap, cheap laser engraver from one of the familiar Chinese resellers. It’s a simple affair with aluminum extrusions, a diode laser, and a control board that seems like it was taken from a 3D printer controller designed five years ago. Now, [Marko] is building some upgrades for this engraver and his PCB production skills have gone through the roof.

The laser engraver [Marko] picked up is called the EleksMaker, and lucky for him there are quite a few upgrades available on Thingiverse. He found two 3D printable parts, one that keeps the belt parallel to the aluminum extrusion, and another that provides adjustable x-axis tightness on the belt. With these two mods combined, [Marko] actually has a nice, smooth motion platform that’s more precise and makes better engravings.

These upgrades weren’t all 3D-printable; [Marko] also got his hands on a few Trinamic TMC2130 stepper motor drivers. These stepper drivers are the new hotness in 3D printing and other desktop CNC machines, and looking at the waveform in an oscilloscope, it’s easy to see why. These drivers produce a perfectly smooth waveform via interpreted microstepping, and they’re almost silent in operation. That’s terrible if you want to build a CNC chiptune player, but great if you want smooth engraving on a piece of copper clad board.

This project has come a long way since the last time we took a look at it a few months ago, and the results just keep getting better. [Marko] is making real PCBs with a laser engraver that cost less than $200, and the upgrades he’s already put into it don’t add up to much, either. You can take a look at [Marko]’s progress in the video below.

Thanks [dechemist] for the tip.

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