A frosted glass disk with geometrical markers

Using A Laser Cutter To Replicate An Optical Comparator Screen

May 30, 2022 by Robin Kearey 13 Comments

Precision instruments often contain specialized components that are essential to their function, but nearly impossible to replace if they fail. [Andre] had just such a problem with an optical comparator, which is an instrument typically used in machine shops to help check the tolerances of a finished part. It does this by projecting a magnified picture of an object onto a glass screen with markings showing angles and distances.

In the old comparator [Andre] bought on eBay, the markings on the glass had faded to such a degree that the instrument was almost unusable. So he contacted [James] over at Clough42, who was able to create a near-perfect replacement screen by using a laser cutter, as shown in the video embedded below.

The first step was to replicate the screen’s markings in a CAD program. [James] explains the process in Fusion 360, demonstrating how you can generate all the different scales nearly automatically through the proper use of constraints, variables and patterns. He then transferred the drawing to Lightburn, which drives the laser cutter and etches the markings into a sheet of glass covered with CerMark, a marking solution that turns a deep black when heated by a laser.

After etching, the final step was to apply frosting to the glass to turn it into a projection screen. While there are several ways to achieve this, [James] went for a simple spray-based method that gave surprisingly good results. It took a few experiments to find out that etching the markings on the back of the glass and applying the frosting on that side as well gave the best combination of sharpness and durability.

[James]’s project shows that even delicate instruments with custom glass components can be repaired, if you just have the right tools. A similar strategy might also work for creating custom scales for analog meters, or even old radio dials. If you’re not familiar with laser cutters, have a look at our experiments with an Ortur model. Thanks for the tip, [poiuyt]!

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Laser-Engraving Hairlines: When A Line Isn’t A Line

May 29, 2022 by Donald Papp 8 Comments

When is a line not a line? When it’s a series of tiny dots, of course!

The line is actually tiny, laser-etched craters, 0.25 mm center-to-center.

That’s the technique [Ed Nisley] used to create a super-fine, colored hairline in a piece of clear plastic — all part of his project to re-create a classic Tektronix analog calculator from the 1960s, but more on that in a moment.

[Ed] tried a variety of methods and techniques, including laser engraving a solid line, and milling a line with an extremely tiny v-tool. Results were serviceable, but what really did the trick was a series of tiny laser-etched craters filled in with a red marker. That resulted in what appears — to the naked eye — as an extremely fine hairline. But when magnified, as shown here, one can see it is really a series of small craters. The color comes from coloring in the line with a red marker, then wiping the excess off with some alcohol. The remaining pigment sitting in the craters gives just the right amount of color.

This is all part of [Ed]’s efforts to re-create the Tektronix Circuit Computer, a circular slide rule capable of calculating all kinds of useful electrical engineering-related things. And if you find yourself looking to design and build your own circular slide rule from scratch? We have you covered.

Adjustable Workholding For Honeycomb Tables, With A Bit Of DIY

May 29, 2022 by Donald Papp 6 Comments

Honeycomb tables are often found on laser cutters, where they provide a way for work material to be laid flat while not interfering with things like airflow. This leads to a cleaner laser cut and a nicer finish, but if one’s work depends on precise positioning and placement, they leave something to be desired because there’s no good way to attach rails, jigs, or anything of the sort in an easy and stable fashion.

The solution [Ed] found for this was to make himself some adjustable offset stops designed to fit into his laser cutter’s honeycomb table. Each consists of a laser-cut disc of wood, which is screwed off-center into an acetal “plug” sized to fit into the vertical gaps in the honeycomb table. This allows each disc to be rotated to fine-tune positioning. With the help of some T-shaped pegs that are also sized to fit into the honeycomb table, [Ed] has all he needs to fix something like a workpiece or jig into a particular and repeatable position.

The whole thing depends on a friction fit, so the sizing of the plug needs to match a particular honeycomb table’s construction. We think this makes it a good match for 3D printing, as one can measure and print plugs (perhaps employing the Goldilocks approach) that fit with just the right amount of snug.

Honeycomb tables are fantastic for laser cutting, but if you find yourself in a pinch for a replacement, an old radiator can make a pretty decent stand-in.

The laser driver's internals, showing the custom PCB, the PSU, connectors and the interlocks.

Laser Driver Design Keeps Safety First

May 29, 2022 by Arya Voronova 20 Comments

[Les] from [Les’ Lab] has designed a driver for laser diodes up to 10 watts, and decided to show us how it operates, tells us what we should keep in mind when designing such a driver, and talks about laser safety in general. This design is an adjustable current regulator based on the LM350A, able to provide up to 10 watts of power at about 2 volts – which is what his diode needs. Such obscure requirements aren’t easily fulfilled by commonly available PSUs, which is why a custom design was called for.

He tells us how he approached improving stability of the current regulation circuit, the PCB design requirements, and planning user interface for such a driver. However, that’s just part of the battle – regulating the current properly is important, but reducing the potential for accidental injuries even more so. Thus, he talks extensively about designing the driver circuit with safety in mind – using various kinds of interlocks, like a latching relay circuit to prevent it from powering up as soon as power is applied.

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Building Petahertz Logic With Lasers And Graphene

May 17, 2022 by Al Williams 19 Comments

There was a time when we thought a 50 MHz 486 was something to get excited about. In comparison, the computer this post was written on clocks in at about 3.8 GHz, which these days, isn’t an especially fast machine. But researchers at the University of Rochester and the Friedrich-Alexander-Universität Erlangen-Nürnberg want to blow the doors off even the fastest modern CPUs. By using precise lasers and graphene, they are developing logic that can operate at nearly 1 petahertz (that’s 1,000,000 GHz).

These logic gates use a pair of very short-burst lasers to excite electrical current in graphene and gold junctions. Illuminating the junctions very briefly creates charge carriers formed by electrons excited by the laser. These carriers continue to move after the laser pulse is gone. However, there are also virtual charge carriers that appear during the pulse and then disappear after. Together, these carriers induce a current in the graphene. More importantly, altering the laser allows you to control the direction and relative composition of the carriers. That is, they can create a current of one type or the other or a combination of both.

This is the key to creating logic gates. By controlling the real and virtual currents they can be made to add together or cancel each other out. You can imagine that two inputs that cancel each other out would be a sort of NAND gate. Signals that add could be an OR or AND gate depending on the output threshold.

[Ignacio Franco], the lead researcher, started working on this problem in 2007 when he started thinking about generating electrical currents with lasers. It would be 2013 before experiments bore out his plan and now it appears that the technique can be used to make super fast logic gates.

We often pretend our logic circuits don’t have any propagation delays even though they do. If you could measure it in femtoseconds, maybe that’s finally practical. Then again, sometimes delays are useful. You have to wonder how much the scope will cost that can work on this stuff.

Light Whiskers From Soap Bubbles Is Real Science

May 15, 2022 by Al Williams 8 Comments

You might think that anything to do with a soap bubble is for kids. But it turns out that observing light scattering through a soap bubble produces unexpected results that may lead to insights into concepts as complex as space-time curvature. That’s what [stoppi] says in his latest experiment — generating “light whiskers” using a laser and a soap bubble. You can watch the video, below, but fair warning: if videos with only music annoy you, you might want to mute your speakers before you watch. On the other hand, it almost seems like a laser light show set to music.

The setup is simple and follows a 2020 Israeli-American research paper’s methodology. A relatively strong laser pointer couples to a fiber-optic cable through a focusing lens. The other end of the fiber delivers the light to the soap bubble, where it separates into strands that exhibit something called branched flow.

Our physics knowledge isn’t deep enough to explain what’s going on here. However, if you have an interest in reproducing this experiment, it doesn’t look like it takes anything exotic. The original paper has a lot to say on the topic and if that’s too heavy for you, there’s always the Sunday supplement version.

If there is ever a practical application for this, we’ll see an uptick in the design of bubble machines. Oddly, this isn’t the first time we’ve seen lasers married with bubbles.

The laser module shown cutting shapes out of a piece of cardboard that's lying on the CNC's work surface

Giant CNC Partners With Powerful Laser Diode

April 30, 2022 by Arya Voronova 13 Comments

[Jeshua Lacock] from 3DTOPO owns a large-format CNC (4’x8′, or 1.2×2.4 m), that he strongly feels is lacking laser-cutting capabilities. The frame is there, and a 150 W CO2 laser tube has been sitting in a box for ages – what else could you need? Sadly, at such a scale, aligning the mirrors is a tough and finicky job – and misalignment can be literally blinding. After reading tales about cutters of such size going out of alignment when someone as much as walked nearby, he dropped the idea – and equipped the CNC head with a high-power laser diode module instead. Having done mirror adjustment on a few CO2 tube-equipped lasers, we can see where he’s coming from.

Typically, the laser modules you see bolted onto CNC heads are firmly under three watts, which is usually only enough for engraving. With a module that provides 5 watts of optical power, [Jeshua] can cut cardboard and thin plywood as well he tells us even 10 W optical power modules are available, just that he didn’t go for one. We reckon that 20 W effective power diodes are not that far into our future, which is getting very close to the potential of the blue box “40 W but actually 35 W but actually way less” K40 laser cutters we cherish. [Jeshua]’s cutter is not breaking speed limits, but it’s built on what’s already there, and the diode is comparatively inexpensive. Equipped with a small honeycomb surface and what seems to be air assist, it’s shown in the video cutting an ornamental piece out of cardboard!

We hackers have been equipping CNCs with laser diodes for a while, but on a way smaller scale and with less powerful diodes – this is definitely a step up! As a hacker, you should have at least some laser cutting options at your disposal, and this overview of CO2 cutters and their availability can get you started. We’ve also given you detailed breakdowns about different sides of laser cutting, be it the must-have of safety, or the nice-to-have of air assist.

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