Laser Hacks

687 Articles

Laser Your Way To Smoother FDM 3D Prints

August 29, 2026 by 13 Comments

Now, not everyone minds the characteristic layer lines you get with Filament Deposition Modeling (FDM) 3D prints, but sometimes you need a smooth surface. If so we might go for filling primer, Bondo, or maybe break out the ABS and vapor smooth. Well, [I changed a thing] has an alternate suggestion: lasers. Laser melting can smooth the walls on a print, or the top surfaces as he shows in two different videos, both embedded below. The results look roughly similar to vapor smoothing, without the chemical exposure small risk of explosion.

Of course, you need a laser to do this, and [I changed a thing] has two diode lasers mounted to the X-axis of his printer. Of the two, the top surfaces were a lot easier to get right than the wall smoothing, which makes sense. Top surfaces are right there for the laser to get at, after all, while with his laser setup [I changed a thing] needs to get at the walls obliquely. [I changed a thing] tries melting layer-by-layer as well as a few methods to get at the walls of a finished print; which works best seems to depend on the size of and geometry of the object, so it looks like this technique is as much art as science right now.

This effort is closely related to the previous work [I changed a thing] did on improving layer adhesion with laser melting.  It’s also not the first time we’ve seen laser-driven print smoothing, but that project used non-planar movements to do a post-print laser pass.

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Laser Layers For (Almost) Isotropicly Strong Prints

August 16, 2026 by 36 Comments

If there’s one defining factor about 3D printing you have to account for when you’re making a design, it’s probably layer adhesion. Sure, there are a lot of factors to consider, but having the z-axis of your part dramatically weaker than x- and y- is a pretty big deal in a whole lot of applications. [I Changed a thing] changed a thing to fix that — namely, he changed his 3D printer by strapping a couple of lasers to it. That’s the kind of hack we like to see!

What the lasers are doing is a very simple idea: they’re pre-melting the last-laid-down-layer just under the nozzle so that molten plastic is meeting molten plastic to create a much stronger joint than you get when you extrude onto an already-cold layer. The second layer keeps the hotspot warmer longer, which also helps the bond. The resulting parts are not purely isotropic, but he’s getting breaking strain along the z-axis of ABS that’s up to 94% of what he’s measuring in the x direction, while PLA still rates at 77.9%. That’s compared to 60% and 41%, for un-lasered samples, respectively. If you watch the video, you’ll get all the details for the printing process and can see more test data.

These lasers look like a game-changer, but their mass might slow down the fast coreXY printers that are so popular these days. If you don’t want to slow down, remember that changing your layer patterns can boost a print’s strength on its own.

Thanks to [Josh Pensel] for the tip!

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Transmitting Analog Video Via Frikkin’ Laser Beams

August 9, 2026 by 14 Comments

Transmitting analog video via photons is old hat: that’s how everything started, after all, back in the day with over-the-air TV. Up the frequency of those photons from radio to visible light, though? Well, now that’s rather interesting. [Daniel] aka [milar111]’s LYME 101– which doesn’t seem to stand for anything–laser-video transmitter/receiver pair was a strong contender in the recently-completed Frikken’ Laser Beams challenge, but somehow we missed putting it up on the blog.

The project is documented quite well on GitHub as linked above, as well as on Instructables, and Hackaday.io, and in a YouTube video we’ve embedded below so you can see it in action. In principle it’s pretty simple: a Raspberry Pi is used to generate the composite video signal, which modulates a red laser diode through a 2N2222 NPN transistor and some passives. The reciever is a BPW34 photodiode wired with reverse bias for speed and fed through a LM318N op-amp. To get +9V and -9V for this circuit, [Daniel] makes the easy hack of using a pair of 9V batteries for a noiseless dual supply. It hooks up to a CRT just fine, but a little finessing in the form of a terminator resistor and a DC bias pot on the transmitter were needed to get his USB capture card working with the signal.

It’s not the weirdest way we’ve seen people hack analog video signals– there’s no audio cassettes to be seen,  and the signal isn’t even SECAM, the oddest encoding— but that’s not a slight. Transmitting video with higher-than-normal-frequency photons might not be that weird, but it looks like a lot of fun.

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Yellow YAG Produces Powerful Pulses In Les’ Leftover Laser

August 4, 2026 by 7 Comments

[Les] likes lasing lasers, and who doesn’t? [Les] likes larger lasers than lots of folks, with his current project being an Nd:YAG (that’s Neodymium:Yttrium Aluminum Garnet) flash pumped laser intended for tattoo removal. Like most of its ilk, the YAG crystal at the heart of that device is a rosy purple color, so when [Les] spotted a Yellow YAG with different doping promising powerful pulses, he purchased it promptly.

Specifically, the retailer was claiming a 30-50% efficiency increase for this yellow rod, thanks to cerium doping. It’s still considered an Nd:YAG, though you can label it as an Nd:Ce:YAG for clarity. The efficiency gain comes from the cerium atom taking unused energy from the flashbulb pulse — which is much broader-wavelength than the thin absorption line of the Nd ions in the rod — and giving that energy to the Nd atoms that do the lasing via fluorescence. He doesn’t try it, but reports on a paper showing these crystals can actually lase with reasonable efficiency from sunlight alone, which we’d love to see. Send us a tip if you try.

His original Nd:YAG rod produced 72.8 mJ pulses, while in the same setup with the yellow laser is peaking at 153 mJ, more than double the original output. That’s even better than the 30-50% [Les] expected, but he reckons it is because the old YAG is, well, old. The coatings break down over time, and UV light from the flashbulbs degrades the crystals too. That’s another benefit of tossing cerium in there, as apparently it acts as sunscreen for your laser rod. It lasts longer and works better, making it a no-brainer of an upgrade.

We’ve seen [Les]’s laser-based hacking before, like this  diode-laser PSU and we’re always glad to take a look with our remaining eye. We also featured his tattoo removal laser back when he started working on it, along with less-lasery projects like his crystal-growing rig.

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Congratulations To The Frikkin Laser Winners!

August 3, 2026 by 8 Comments

Apparently you all love lasers just as much as we do. We put out a challenge to use, build, or otherwise abuse our favorite coherent light sources, and you responded. Some of the projects had been in the works for quite a while and were ridiculously polished, some were whipped together on the fly just for the contest, and we truly enjoyed both.

We only have three $150 DigiKey gift certificates to give out, though, so without further ado, we present to you…

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A plastic device sits on a desk, with a computer display and an oscilloscope behind it. A fiber-optic cable runs from the device to a laser diode source.

2026 Frikkin Lasers Challenge: Measuring Nanometer-Scale Displacements With An Optical Cavity

July 26, 2026 by 4 Comments

Optical cavities – two mirrors arranged to reflect light multiple times between them – form the basis of lasers and certain optical filters. Since any angle between the two mirrors results in light being scattered away, parallel alignment is essential, yet difficult to maintain. Nevertheless, [Timothy Giles] managed to 3D-print and align such an optical cavity, and used it to detect minute shifts in space and wavelength.

The cavity has two semi-transparent mirrors facing towards each other. One mirror is held in a 3D-printed mount, and the other is attached to the diaphragm of a speaker with a hole drilled through the center. The hole avoids the speaker coil, and allows light exiting the optical cavity through the semi-transparent mirror to appear on a paper target, which is monitored by a webcam. On the other side of the optical cavity, a laser diode coupled to a single-mode fiber shines in through the other mirror. Alignment is challenging, but the webcam makes it easier; as the mirrors tilt relative to each other, the pattern seen on the paper target changes, providing feedback for more precise adjustment.

Light reflected within the cavity can interfere constructively or destructively with incoming light, changing the brightness of the emitted beam. [Tim] used the speaker as a linear actuator to vary the cavity’s length, which, by counting the peaks in brightness, allowed him to measure the diaphragm’s displacement. This also demonstrated a laser diode’s wavelength instability: when the cavity was set to a constant length and the laser started up, the output brightness would cycle a few times. As the diode was warming up, its output wavelength was shifting, creating the same changing interference pattern.

To get a Gaussian beam distribution, [Tim] used a fiber-coupled laser; if you’d like to build one, we’ve seen a coupling mechanism built before. Most lasers are built around an internal optical cavity, but some instead use an external cavity.

2026 Hackaday Freaking Lasers Contest
A scanning-electron micrograph is shown of a cricket's body, focusing on the head, which has been sliced off just above the eyes.

Cross-Sectioning Crickets With A Femtosecond Laser

July 18, 2026 by 15 Comments

Unlike most cutting lasers, femtosecond lasers don’t vaporize materials; rather, they produce such short, intense bursts of light that the affected region is ablated without having the chance to heat its surroundings. This makes them good at cutting away material without damaging the surroundings, something [Ben Krasnow] exploited to cut cross-sections of samples while still in a scanning-electron microscope.

In this case, the samples were crickets, and before imaging they had to be prepared. First, the bodies were soaked in glutaraldehyde to cross-link the proteins and stabilize the structure. Next, a series of solvent exchanges replaced the water in the bodies with a low-surface-tension solvent; this meant that during the next step, drying, surface tension wouldn’t distort the crickets’ internal structure. Finally, the insect bodies were charred under argon, which made the bodies conductive and more absorptive to laser light.

The laser itself and the scanning galvo are mounted outside the microscope, and shine in through a transparent window. To protect the detector and electron optics from a spray of ablated carbon, a servo motor swings an aluminium shutter between these and the sample while the laser is active. This caused some mysterious problems during testing: after the first ablation run, the electron microscope’s image would contain so much noise as to be unusable, but it would improve over time. As it turned out, the shutter was painted, and the other side of the paint was getting coated with charged carbon particles. This created a small capacitor which disrupted the electron optics as it discharged. Eventually, after solving this and a few other strange problems, [Ben] was able to take several time-lapse videos of the laser gradually ablating a cricket, 30 microns at a time, revealing its inner structure.

Although scanning-electron microscopes are unfortunately shard to come by, it’s still possible to restore a secondhand microscope or, as [Ben] did, build your own. Femtosecond lasers are yet more inaccessible, though they can be used to replicate themselves.

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