If you’ve got a laser cutter, it is highly probable that it uses a laser diode. But more expensive machines use a carbon dioxide laser tube along with mirrors. There was a time when these lasers came in two flavors: very expensive and amazing or moderately expensive and cheaply made. However, we are seeing that even the moderately expensive machines are now becoming quite advanced. [Chad] reviews a 55-watt xTool P2. At around $5,000, it is still a little spendy for a home shop, but it does have pretty amazing features. We can only hope some less expensive diode lasers will adopt some of these features.
[Chad’s] video that you can see below attempts to recreate some of the amazing things xTool did on their product introduction live stream. He was able to recreate most, but not all of the results. In some cases, he was also able to do better.
[NASA] Astronauts will be testing the Orion Artemis II Optical Communications System (O2O) to transmit live, 4K ultra-high-definition video back to Earth from the Moon. The system will also support communication of images, voice, control channels, and enhanced science data.
Aboard Orion, the space terminal includes an optical module, a modem, and a control system. The optical module features a four inch telescope on a dual gimbal mount. The modem modulates digital information onto laser beams for transmission back to Earth, and demodulates data from laser beams recieved from Earth. The control system interfaces with avionic systems aboard Orin to control and point the communications telescope.
On Earth, facilities including the Jet Propulsion Laboratory and the White Sands Complex will maintain high-bandwidth optical communication links with Orion. Information received from Orion will be relayed to mission operations, scientists, and researchers.
NASA’s Laser Communications Relay Demonstration (LCRD) showcases the benefits of optical communications. Traditionally, missions relied upon radio communication, but improved technology will better serve space missions that generate and collect ever-increasing quantities of data. Optical communication solutions can provide 10 to 100 times the bandwidth of radio frequency systems. Other improvements may include increased link distances, higher efficiency, reduced interference, improved security, and reductions in size and weight. Our Brief History of Optical Communication outlines many of these advantages.
Spinning hard drives are being phased out of most consumer-grade computers in favor of faster technology like solid-state drives and their various interfaces. But there’s still millions of them in circulation that will eventually get pulled from service — so what do we do with them? If you’ve got one that would otherwise be going in the garbage, they can be turned into some other interesting devices like this laser text projector.
Even the slowest drives spin at around 5000 RPM, which is perfect for this type of application. The device works by mounting twelve mirrors, each at a slightly different angle, on a drum which is spun by the drive’s motor. Bouncing a laser off of the spinning drum results in a projection of twelve horizontal lines. By rapidly switching the laser on and off depending on which mirror it’s pointing at, the length of each line can be controlled.
Thanks to persistence of vision, that allows you to show text on the surface that the laser is projected on. At speeds this high, it took [Ben] of Ben Makes Everything quite a few iterations to get it to a usable space. From sensors that were too slow to lasers not bright enough to 3D prints that were not accurate enough, he goes through the design of his build and the process in excellent detail.
After solving all of the problems including building his own constant-current laser power supply, and burning up a few laser diodes in the process, [Ben] has a laser projector capable of displaying readable text at a great distance which is also portable, running on a 12 V power supply. There are some possible areas of improvement that he notes as well, such as an unbalanced 3D printed part causing a bit of a wobble and the Arduino controller not being fast enough for more text. But it’s an impressive project nonetheless, similar to a two-mirror version we saw some time ago but with the ability to display text as well.
Nothing beats a laser cutter and a sheet of Baltic birch plywood or MDF when it comes to making quick, attractive enclosures. Burning out all the pieces and fitting them together with finger joints is super satisfying — right up until you realize that you didn’t quite get the kerf allowance right, and your pieces don’t fit together very nicely. If only there was a way to automate kerf measurement.
There is, in the form of Kerfmeter. It comes to us by way of the lab of [Patrick Baudisch] at the University of Potsdam, where they’ve come up with a clever way to measure the kerf of a laser cutter right during the cutting session. With the Kerfmeter mounted directly to the laser cutter head, a small test artifact based on an Archimedean spiral is cut into a corner of the workpiece. Pins on a small motor engage with the object and turn it until it jams in its hole; the wider the kerf, the greater the angle. Once the kerf is calculated, the rest of the design can be dilated by the proper amount to achieve a perfect fit. The video below shows it better than words can explain it.
What we like about this is its simplicity — all it involves is a motor and a microcontroller, plus a little software. It seems much faster than using a traditional kerf gauge, not to mention more precise. And while it does use up a little bit of material, the test pattern is really pretty small, all things considered. Seems like a reasonable trade-off to us. Still, if you want to figure out your kerfs the old-fashioned way, we’ve got you covered.
Before video games, there were pinball machines. Not that they don’t exist today, but a modern pinball machine will likely have microprocessors and other fancy things that traditional pinball machine designers could never dream of. [Eli] had one of these mechanical machines from 1974 as a kid and, later, encountered a more modern machine with a rudimentary microprocessor and other integrated circuits onboard. One thing this enabled is the ability to remember high scores. But you have to physically look at the machine, and you can only see the top four scores. [Eli] decided to adapt the machine to upload high score data to the Internet, and it is a fun project.
[Eli]’s design goals were to make it automatic and robust. That is, if the network is down or the machine loses power, you shouldn’t lose high score data. In addition, he didn’t want to change the appearance or damage the 40-year-old machine. You can see a video of how it all turned out below.
The Laser Cue machine is one of many built around the “Williams System 7” platform. A 6808 CPU, along with some I/O chips to manage all the lights, sensors, and bells. The game has only 1K of RAM, 12K or ROM, and 128 bytes (no prefix, just bytes) of RAM with battery backup. There was even a common “operating system” called Flipper ROM, and that’s actually documented over on GitHub.
The ESP32 version of the WiFi interface board
Since the memory for the machine is all in external chips, it was a reasonable idea to replace the CPU with a board that monitored signals on the board. The CPU would plug into this new board, and then a newer microcontroller with an Internet connection could eavesdrop on bus traffic. However, removing the old CPU and jamming pins into the ancient socket was worrisome, so instead, [Eli] elected to tap into a test connector that was already on the board but not plugged into anything.
An ESP32 is more than capable of the speeds, although connecting to 5 V logic was a bit of a problem. The CPU has 5 V tolerant pins, but some of the 25 available pins on the development board either set items on boot or may briefly be outputs and were thus unusable. To reduce the necessary pins, [Eli] decided to do some of the decoding in separate logic. Instead of using TTL chips, he elected to use a programmable logic array.
After that, it seemed it would be straightforward, but there was something preventing the ESP32 from reading each bus cycle. [Eli] never got to the bottom of it but instead switched to the Raspberry Pi Pico W. Using the chip’s special I/O processors made the job easy, and it worked perfectly. The rest of the project was just fit and finish. Be sure to read to the end to find out the lessons learned which might help you on your next similar project.
A modern DIY machine might even have an FPGA inside. Don’t have room for a big full-sized pinball machine? No problem.
[PWalsh] was using his lasercutter to cut acrylic, expecting the cuts to have a pleasantly smooth edge. Alas, the edges turned out to be wobbly and sandpaper-like, not smooth in the slightnest. Bummer! Internet suggested a stepper motor swap, but not much in the way of insights – and that would’ve been a royal pain for sure. How would you approach debugging such a problem? Well, [PWalsh] didn’t want to swap crucial components willy-nilly, going the scientific way instead, and breaks it down for us.
Having compiled an extensive list of possible places to look for a fault in, he started going through fundamental assumptions. Do other lasercutters experience this issue? No, even the cheap ones can cut things properly. Is it water level causing intermittent cooling? Nope, not that. Is it the stepping settings? Tweaked, not that. Laser pulsing frequency? No dice. Continue reading “Debugging Laser Cut Wobble, The Scientific Way”→
Laser scanning microscopes are useful for all kinds of tiny investigations. As it turns out, you can build one using parts salvaged from a Blu-ray player, as demonstrated by [Doctor Volt].
The trick is repurposing the optical pickup unit that is typically used to read optical discs. In particular, the build relies on the photodiodes that are usually used to compute focus error when tracking a disc. To turn this into a laser scanning microscope, the optical pickup is fitted to a 3D printed assembly that can slew it linearly for imaging purposes.
Meanwhile, the Blu-ray player’s hardware is repurposed to create a sample tray that slews on the orthogonal axis for full X-Y control. An ESP32 is then charged with running motion control and the laser. It also captures signals from the photodiodes and sends them to a computer for collation and display.
[Doctor Volt] demonstrates the microscope by imaging a small fabric fragment. The scanned area covers less than 1 mm x 1 mm, with a resolution of 127 x 127, though this could be improved with finer pitch on the slew mechanisms.
The trick is repurposing the optical pickup unit that is typically used to read optical discs. In particular, the build relies on the photodiodes that are usually used to compute focus error when tracking a disc. To turn this into a laser scanning microscope, the optical pickup is fitted to a 3D printed assembly that can slew it linearly for imaging purposes.
