DIY Fiber Laser Adds Metal Cutting To The Mix

January 13, 2023 by Dan Maloney 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 Medieval Gothic Monastery Built Using CAD / CAM

January 13, 2023 by Anool Mahidharia 51 Comments

Just because you’re a monk doesn’t mean you can’t use CAD. The Carmelite monks of Wyoming are building a grandiose Gothic Monastery, and it’s awe inspiring how they are managing to build it.

The Carmelite monks needed a new, larger monastery to house their growing numbers, and found a parcel of land near Meeteetse Creek in Wyoming. The design of their new Gothic monastery was outsourced to an architectural firm. Gothic architecture is characterised by key architectural elements such as pointed arches, large stained glass windows, rib vaults, flying buttresses, pinnacles and spires, elaborate entry portals, and ornate decoration.

After some research, the monks settled on using Kansas Silverdale limestone for the monastery. Cutting and carving the elaborate stone pieces required for such a project, within time and cost constraints, could only be achieved using CNC machines. Hand carving was ruled out as it was a very slow process, would cost a whole lot more, and it wouldn’t be easy to find the artisans for the job. So when it came to shortlisting vendors for the vast amount of stone cutting and carving required for construction, the monks found themselves alarmed at how prohibitively expensive it would turn out to be.

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DIY Comparatron Helps Trace Tiny, Complex Objects

December 11, 2022 by Donald Papp 21 Comments

Hackers frequently find themselves reverse-engineering or interfacing to existing hardware and devices, and when that interface needs to be a physical one, it really pays to be able to take accurate measurements.

This is easy to do when an object is big enough to fit inside calipers, or at least straight enough to be laid against a ruler. But what does one do when things are complex shapes, or especially small? That’s where [Cameron]’s DIY digital optical comparator comes in, and unlike commercial units it’s entirely within the reach (and budget) of a clever hacker.

The Comparatron is based off a CNC pen plotter, but instead of a pen, it has a USB microscope attached with the help of a 3D-printed fixture. Serving as a background is an LED-illuminated panel, the kind useful for tracing. The physical build instructions are here, but the image should give most mechanically-minded folks a pretty clear idea of how it fits together.

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Carving Terrain Maps Into Plywood With Software Help

November 28, 2022 by Bryan Cockfield 20 Comments

CNC machines are incredibly versatile tools. At a machine shop, they can machine all kinds of metal and plastic parts. Beyond that, they can engrave various materials including glass, and even create PCBs. [Steve] has a CNC machine of his own creation in his shop, and while he might be employing it for those common uses, his artistic creations are on the showcase for today with these 3D topographic relief maps.

The key to creating a good topographic relief map is good material stock. [Steve] is working with plywood because the natural layering in the material mimics topographic lines very well, especially with the high-quality marine-grade birch plywood he is using. Making sure to select pieces without knots improves the final product substantially, as does taking the time to fill any voids. Selecting good stock is only part of the process though. [Steve] is using TouchTerrain, an open source project helmed by [Dr. Chris Harding] of Iowa State University, to create the model which gets fed to the CNC machine. Originally intended for 3D printing applications, the web-based tool lets you easily select an area on the globe and export its topographical data to a standard STL or OBJ file.

With good stock and the ability to easily create 3D topographic maps, anyone with a CNC machine like this could easily reproduce their terrain of choice. We imagine the process might be easily ported to other tools like 3D printers, provided the resolution is high enough. We have also seen similar builds using laser cutters, although the method used is a little different.

A man and a woman stand at opposite ends of a wooden-framed bicycle. It has 20" tires and a long, black seat. A rack extends over the front tire for carrying small items.

Plywood Bicycle Makes Frame Building More Accessible

November 4, 2022 by Navarre Bartz 37 Comments

Bike frames are simple on the surface, but can quickly become complicated if you want to fabricate one yourself. Brazing and welding tend to be less common skills than knowing how to bolt things together, so [Arquimaña] has brought us the OpenBike to make the process accessible to more people.

An open-source set of files designed for CNCs and 3D printers, the OpenBike uses readily available materials like sheet plywood to make a sturdy, if unconventional-looking, bicycle. Like many other consumer goods, most bike frames are currently built in Asia. This allows for economies of scale, but removes locals from the design process. By using simpler tools, OpenBike allows for more local direction of what features might be needed for a particular region.

Shifting even a small portion of trips to more active forms of transport is an important part of lowering carbon emissions, so making bikes a more attractive means of transportation is always welcome. What might be important in one region might be superfluous and expensive in another (multiple gears in a hilly region, for example). OpenBike could be especially useful as a way to rapid-prototype different feature sets for a particular region before committing to a more traditional frame-building technique for larger batches of bikes.

If you want to see some other bike hacks, why not check out this extending bicycle, this steampunk recumbent trike, or these bike hacks from around the world?

via Yanko Design

Fiber Laser Your Way To Flexible PCB Success!

October 26, 2022 by Jenny List 10 Comments

It’s not often we feel that something we’re featuring is a genuinely new and groundbreaking technique, but a team from the University of Maryland’s Small Artifacts Lab may have done just that with their foldable and flexible PCBs created using a fiber laser engraver.

Laser engraving a PCB is nothing new, but they’ve taken a custom PCB material made using Kapton tape and copper foil, and fine-tuned the engraver to not only selectively remove copper, but also to create in-place folds in the Kapton substrate. They have even used the laser to melt solder paste and solder components, though we’re not so convinced about the quality as seen in the video below the break. This means that they can not only create 3-dimensional PCB sculptures but also useful structures such as their example of an all-PCB micro switch. To make things easy they’ve even created a custom CAD package for designing in this medium.

Perhaps best of all, there appears to be nothing here that couldn’t be also performed outside the lab by anyone with enough Kapton and copper, and a fiber laser. We’re looking forward to where this technique will go. If you’re interested, you can read their paper here.

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