Laser Scanner Upgraded To Use PCB Motor

February 22, 2023 by 10 Comments

[Rik]’s Hexastorm laser scanner project originally used a discrete polygon mirror controller+motor module from Sharp to spin a prism. But the scanner head was a bit difficult to assemble and had a lot of messy wires. This has all been replaced by a single board featuring a PCB-printed motor, based on the work of [Carl Bugeja]. The results are promising so far — see video below the break.

Since the prism is not attached to anything, currently it will fall off if mounted in the intended vertical orientation. One of [Rik]’s next steps is to improve the mount’s design to constrain the spinning prism. The previous Sharp motor was specified to 21000 RPM, but was only driven to 2400 RPM in [Rik]’s first version. This new PCB motor spins at 2000 RPM in these tests, comparable to his previous experiments ( we’re not sure about the maximum RPM ).

See our original writeup from 2019 to review the goals of this project, and be sure to checkout details and documentation on the Hexastorm project page. To learn more about PCB motors, read our article about [Carl]’s first design and visit his Hackaday.io page. Thanks to [Jonathan Beri] for the tip.

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Picking A Laser Hack Chat

February 20, 2023 by 25 Comments

Join us on Wednesday, February 22 at noon Pacific for the Picking a Laser Hack Chat with Jonathan Schwartz!

You’ve got to admit that it’s a pretty cool world to live in that presents a problem like, “Which laser cutter should I buy?” It wasn’t all that long ago that decisions on laser purchases were strictly in the realm of Big Science, and the decision was driven as much by spending grant money as by the specifics of the application. If you were in need of a laser back then, chances are good you had some deep pockets, or at least access to someone else’s pockets.

Fast forward a couple of decades or so and buying a laser is an entirely different exercise. Lasers have become a commodity, and finding the right one depends entirely on your use cases. Lasers are no longer jealously guarded laboratory instruments, but workhorses on the vanguard of the desktop manufacturing revolution. They engrave, they cut, they melt — in short, they do a LOT of work. And it’s up to you to choose the right laser for the job.

join-hack-chatTo help us sort all this out and come up with a plan for figuring out the best laser for any use case, we’ve invited Jonathan Schwartz back on the Hack Chat. Jon dropped by back in March of 2021 to share his wealth of laser experience thanks to his laser-cutting business. This time around we’re going to focus — err, concentrate — oops, drill down — oh, whatever! — on the more practical aspects of buying a laser. We’ll talk about laser types, fiber lasers, applications vs. laser specs — anything you can think of. If you have questions about buying a laser, we’ll have answers!

Our Hack Chats are live community events in the Hackaday.io Hack Chat group messaging. This week we’ll be sitting down on Wednesday, February 22 at 12:00 PM Pacific time. If time zones have you tied up, we have a handy time zone converter.

Click that speech bubble to the right, and you’ll be taken directly to the Hack Chat group on Hackaday.io. You don’t have to wait until Wednesday; join whenever you want and you can see what the community is talking about.

Drilling Glass With Femtosecond Lasers Just Got Even Better

February 16, 2023 by 48 Comments

Glass! It’s a finicky thing. Strong as hell, yet chip it and glance at it the wrong way, and you’re left with a bunch of sharp rubbish. It’s at once adored for its clarity and smoothness, and decried for how temperamental it can be in the case of shock, whether mechanical, thermal, or otherwise.

If you’ve ever tried to drill glass, you’ll know it’s a tough errand. To do so without cracking it is about as likely as winning the lottery on Mars. Even lasers aren’t great at it. However, a research team from France has developed a new technique that uses femtosecond lasers to drill microscopic holes in glass with a minimum of tapering and no cracking! Brilliant, no?
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DIY Fiber Laser Adds Metal Cutting To The Mix

January 13, 2023 by 23 Comments

Sadly, the usual CO2-powered suspects in the DIY laser cutter market are woefully incapable of cutting metal. Sure, they’ll cut the heck out of plywood and acrylic, and most will do a decent job at engraving metal. But cutting through a sheet of steel or aluminum requires a step up to much more powerful fiber laser cutters. True, the costs of such machines can be daunting, but not daunting enough for [Travis Mitchell], who has undertaken a DIY fiber laser cutter build that really caught our eye.

Right off the bat, a couple of things are worth noting here. First — and this should be obvious from the fountains of white-hot sparks in the video below — laser cutters are dangerous, and you should really know what you’re doing before tackling such a build. Second, just because [Travis] was able to cut costs considerably compared to a commercial fiber laser cutter doesn’t mean this build was cheap in absolute terms — he reports dropping about $15,000 so far, with considerable ongoing costs to operate the thing.

That said, there doesn’t appear to be anything about this build that anyone with some experience building CNC machines wouldn’t be able to tackle. The CNC side of this is pretty straightforward, although we note that the gantry, servos, and controller seem especially robust.

The laser itself is an off-the-shelf machine, a Raycus RFL-C1000 fiber laser and head that packs a 1,000-Watt punch. There’s also the required cooling system for the laser, and of course there’s an exhaust system to get rid of the nasty fumes.

All that stuff requires a considerable investment, but we were surprised to learn how much the consumables cost. [Travis] opted for bottled gas for the cutter’s gas assist system — low-pressure oxygen for carbon steel and high-pressure nitrogen for everything else. Refills are really pricey, in part because of the purity required, but since the proper compressor for the job is out of the budget for now, the tanks will have to do. And really, the thing cuts like a dream. Check out the cutting speed and precision in the video below.

This is but the first in a series of videos that will detail the build, and if [Travis] thought this would whet our appetites for more, he was right. We really haven’t seen many DIY fiber laser builds, but we have seen a teardown of a 200-kW fiber laser that might tickle your fancy.

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A White-Light Laser, On The Cheap

January 4, 2023 by 51 Comments

Lasers are known for the monochromatic nature of their light, so much so that you might never have thought there could be such a thing as a white laser. But in the weird world of physics, a lot of things that seem impossible aren’t really, as demonstrated by this dirt-cheap supercontinuum laser.

Of course, we’re not experts on lasers, and certainly not on non-linear optics, so we’ll rely on [Les Wright]’s video below to explain what’s going on here. Basically, a “supercontinuum” is just the conversion of a monochromatic source to a broader spectral bandwidth. It’s a non-linear optical process that’s usually accomplished with expensive bits of kit, like photonic crystal fibers, which are optical fibers with an array of tiny air-filled holes running down their lengths. Blast a high-intensity monochromatic laser down one end, and white light comes out the other end.

Such fibers are obviously fantastically expensive, so [Les] looked back in the literature and found that a simple silica glass single-mode fiber could be used to produce a supercontinuum. As luck would have it, he had been experimenting with telecom fibers recently, so along with a nitrogen laser he recovered from a Dumpster, he had pretty much everything he needed. The final setup uses the UV laser to pump a stilbene dye laser, which shoots a powerful pulse of 426 nanometer light into about 200 meters of fiber, and produces a gorgeous supercontinuum containing light from 430 nm to 670 nm — pretty much the entire visible spectrum.

It’s great to see projects like this that leverage low-cost, easy-to-source equipment to explore esoteric physics concepts.

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A closeup picture showing the jagged edge of the cut

Debugging Laser Cut Wobble, The Scientific Way

December 29, 2022 by 23 Comments

[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 Cut Clips Save A Lamp From The Trash

December 25, 2022 by 6 Comments

Ikea have been known for years as a purveyor of inexpensive  yet stylish homewares, but it’s fair to say that sometimes their affordability is reflected in their insubstantial construction. Such is the case with the Sjöpenna lamp, whose construction relies on rubber bands. On [Tony]’s lamp these bands degraded with age, causing it to fall apart. The solution? A set of cleverly-designed laser-cut clips to replace them.

The challenge to replacing a stretchy material with a rigid one is that it must have enough ability to bend without snapping as it is put in place. For this he selected PETG, with 0.04″ (about 1 mm thick) hitting the sweet spot. His photos demonstrate with some green tape added for visibility, how the clip bends backwards just far enough to fit over where the rubber band once located, and then flips back neatly to hold it all in place.

If you have a collapsing Ikea lamp then this will be just what you need, but this hack goes further than that. A frequent requirement for repairs is some kind of clip, because clips are always the first to break, This technique for laser cutting them is a handy one to remember, next time your design needs a springy bit of plastic.