Squares of sample materials placed on the laser bed awaiting the sensing head

Smart Laser Cutter Ad-on Detects Material Optically

September 6, 2021 by Dave Rowntree 9 Comments

Come on now, admit it. You’ve done it. We’ve done it. You know — you were really sure that sheet of plastic stock you found lying around the hackerspace was acrylic right? You dialled in the settings, loaded the design, set the focus and pushed the little green ‘start’ button. Lots of black smoke, fire, and general badness ensued as you lunged for the red ‘stop’ button, before lifting the lid to work out how you’re going to clean this one up.

That was not acrylic. That was polycarbonate.

What you need is the latest gadget from MIT: SensiCut: A smart laser cutter system that detects different materials automatically.

The technique makes use of so-called ‘speckle imaging’ where a material illuminated by a laser will produce a unique pattern of reflected spots, or speckles into a camera. By training a deep neural model with a large set of samples, it was found possible to detect up to 30 types of material with 98% accuracy.

The pre-baked model runs on a Raspberry PI zero with an off-the-shelf camera all powered from a power bank. This allows the whole assembly to simply drop onto an existing laser cutter head, with no wiring needed.

Even if you’re a seasoned laser cutter user, with a well-controlled stock pile, the peace-of-mind this could give would definitely be worth the effort. A more detailed description and more videos may be found by reading the full paper. Here’s hoping they release the system as open source, one day in the not-to-distant future. If not, then, you know what to do :)

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Thor does battle with a man shooting lasers from his hands

Of Lasers And Lightning: Thwarting Thor With Technology

August 17, 2021 by Adam Zeloof 45 Comments

Most of us don’t spend that much time thinking about lightning. Every now and then we hear some miraculous news story about the man who just survived his fourth lightning strike, but aside from that lightning probably doesn’t play that large a role in your day-to-day life. Unless, that is, you work in aerospace, radio, or a surprisingly long list of other industries that have to deal with its devastating effects.

Humans have been trying to protect things from lightning since the mid-1700s, when Ben Franklin conducted his fabled kite experiment. He created the first lightning rod, an iron pole with a brass tip. He had speculated that the conductor would draw the charge out of thunderclouds, and he was correct. Since then, there haven’t exactly been leaps and bounds in the field of lightning rod design. They are still, essentially, a metal rods that attract lightning strikes and shunt the energy safely into the earth. Just as Ben Franklin first did in the 1700s, they are still installed on buildings today to protect from lightning and do a fine job of it. While this works great for most structures, like your house for example, there are certain situations where a tall metal pole just won’t cut it.

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Using A Laser To Blast Away A Bayer Array

August 9, 2021 by Stephen Ogier 47 Comments

A Bayer array, or Bayer filter, is what lets a digital camera take color photos. It’s an array of tiny color filters that sit on top of a camera’s CCD. The filter makes it so that each sub-pixel in the image sensor only sees red, green, or blue light. The Bayer filter is an elegant tool that gives us color digital photos, but what would you do if you wanted to remove one?

[Les Wright] has devised a way to remove the Bayer filter from the Raspberry Pi Camera. Along with filtering red, green, and blue light for their respective sensors, Bayer filters also greatly reduce the amount of UV and IR light that make it to the CCD sensor. [Les] uses the Raspberry Pi camera in his Pi-based Spectrometer, and he wants to remove the Bayer filter to improve and expand its sensitivity.

Of course, [Les] isn’t the first one to want to do this. Some have succeeded in physically scratching the filter off of the CCD, but because the Pi Camera has vital circuitry around the outside of the sensor, scratching the filter off would likely destroy the circuitry. Others have stripped it off using chemical means, so [Les] gave this a go and destroyed no small number of cameras in his attempt to strip the filter off with solvents like DMSO, brake fluid, and industrial paint stripper.

A look at the CCD, halfway through the process.

Inspired by techniques used in industry, [Les] eventually tried to use a several-kW nitrogen laser to burn off the filter (which seems appropriate given his experience with lasers). He built a rig that raster scans the laser across the sensor using stepper motors to drive micrometer bases. A USB microscope was included to allow progress to be monitored, and you can see a change in the sensor’s appearance as the filter is removed.

After blasting off the Bayer filter, [Les] plugged his improved camera into his home-built spectrometer and pointed it outside. The new camera gives the spectrometer much more uniform sensitivity and allows [Les] to see further into the IR and UV bands. The spectrometer can even detect the Fraunhofer lines—subtle dips in the sun’s spectrum from absorption by molecules in the atmosphere.

This is incredible for a DIY setup and instrument, and we can’t wait to see what [Les] does next to improve his measurements. If your spectrometry needs are more mass than visual, take a look at this home-built mass spectrometer. Home spectrometers aren’t just for examining light spectra—they can also be used to judge the ripeness of fruit!

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Laser Augmented Reality Glasses Show You The Way

July 8, 2021 by Tom Nardi 52 Comments

Tech companies like Google and Microsoft have been working on augmented reality (AR) wearables that can superimpose images over your field of view, blurring the line between the real and virtual. Unfortunately for those looking to experiment with this technology, the devices released so far have been prohibitively expensive.

While they might not be able to compete with the latest Microsoft HoloLens, these laser AR classes from [Joel] promise to be far cheaper and much more approachable for hackers. By bouncing a low-power laser off of a piezo-actuated mirror, the hope is that the glasses will be able to project simple vector graphics onto a piece of reflective film usually used for aftermarket automotive heads-up displays (HUDs).

Piezo actuators are used to steer the mirror.

[Joel] has put together a prototype of what the mirror system might look like, but says driving the high-voltage piezo actuators poses some unique challenges. The tentative plan is to generate the vector data with a smartphone application, send it to an ESP32 microcontroller within the glasses, and then push the resulting analog signals through a 100 V DC-DC boost converter to get the mirror moving.

We’ve seen the ESP32 drive a laser galvanometer to play a game of Asteroids, but recreating such a setup in a small enough package to fit onto a pair of glasses would certainly be an impressive accomplishment. Early tests look promising, but clearly [Joel] has quite a bit of work ahead of him. As a finalist for the Rethink Displays challenge of the 2021 Hackaday Prize, we’re looking forward to seeing the project develop over the coming months.

Fake: A Laser Display Board Of Your Very Own

June 21, 2021 by Jenny List 64 Comments

Update 6/23/21: Many people have called this out as fake. When viewed at 1/4 speed, you can see the logos in the YouTube video are always full-off or full-on and never caught mid way through a scanned frame. The images may be projected from off-camera to the left, rather than by the diode behind the screen. It’s a neat idea, but on closer review the demo provided smells a bit fishy so we’ve added a “Real or Fake” tag and updated the title. Update #2: [Kanti Sharma] wrote into the tipsline apologizing for the faked video, saying that he tried to get it to work but couldn’t and then “used a phone and a lens to fake the laser”. Thanks for fessing up to this one.

There are some times when an awesome project comes into your feed, but a language barrier intervenes as you try to follow its creator’s description. [Kanti Sharma]’s laser display appears to be a fantastic piece of work, but YouTube’s automatic translations in the video below make so little sense as to leave us Anglophones none the wiser as to what he’s saying. The principle comes across without need for translation though: he’s taken a laser diode module and is using it to create a vector scan by mounting it in the middle of a set of coils driven through beefy FETs by an Arduino. It’s an electromagnetic take on the same principle used in a CRT vector displays such as the famous Vectrex console, with the beam of electrons replaced with laser light.

It’s a technique not unlike what’s been used for years in the lighting industry, in which much larger laser displays are created with mirrors mounted on galvanometers. There must be a physical limit at which the weight of the laser slows down the movement, but if the video is to be believed it’s certainly capable of displaying graphics on a screen.

People have done a lot of things with lasers on these pages, but there have been surprisingly few vector displays using them. Here’s one from nearly a decade ago.

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Repairing A 300W CO2 Laser, One Toasted Part At A Time

June 16, 2021 by Tom Nardi 27 Comments

A couple months back, [macona] got his hands on a 300 watt Rofin CO2 laser in an unknown condition. Unfortunately, its condition became all too known once he took a peek inside the case of the power supply and was confronted with some very toasty components. It was clear that the Magic Smoke had been released with a considerable bit of fury, the trick now was figuring out how to put it back in.

The most obvious casualty was an incinerated output inductor. His theory is that cracks in the ferrite toroid changed its magnetic properties, ultimately causing it to heat up during high frequency switching. With no active cooling, the insulation cooked off the wires and things started to really go south. Maybe. In any event, replacing it was a logical first step.

If you look closely, you may see the failed component.

Unfortunately, Rofin is out of business and replacement parts weren’t available, so [macona] had to wind it himself with a self-sourced ferrite and magnet wire. Luckily, the power supply still had one good inductor that he could compare against. After replacing the coil and a few damaged ancillary wires and connectors, it seemed like the power supply was working again. But with the laser and necessary cooling lines connected, nothing happened.

A close look at the PCB in the laser head revealed that a LM2576HVT switching regulator had exploded rather violently. Replacing it wasn’t a problem, but why did it fail to begin with? A close examination showed the output trace was shorted to ground, and further investigation uncovered a blown SMBJ13A‎ TVS diode. Installing the new components got the startup process to proceed a bit farther, but the laser still refused to fire. Resigned to hunting for bad parts with the aid of a microscope, he was able to determine a LM2574HVN voltage regulator in the RF supply had given up the ghost. [macona] replaced it, only for it to quickly heat up and fail.

Now this was getting ridiculous. He replaced the regulator again, and this time pointed his thermal camera at the board to try and see what else was getting hot. The culprit ended up being an obsolete DS8922AM dual differential line transceiver that he had to source from an overseas seller on eBay.

After the replacement IC arrived from the other side of the planet, [macona] installed it and was finally able to punch some flaming holes with his monster laser. Surely the only thing more satisfying than burning something with a laser is burning something with a laser you spent months laboriously repairing.

We love repairs at Hackaday, and judging by the analytics, so do you. One of this month’s most viewed posts is about a homeowner repairing their nearly new Husqvarna riding mower instead of sending it into get serviced under the warranty. Clearly there’s something about experiencing the troubleshooting and repair process vicariously, with our one’s own hardware safely tucked away at home, that resonates with the technical crowd.

With A Big Enough Laser, The World Is Your Sensor

May 21, 2021 by Tom Nardi 31 Comments

It’s difficult to tell with our dull human senses, but everything around us is vibrating. Sure it takes more energy to get big objects like bridges and houses humming compared to a telephone pole or mailbox, but make no mistake, they’ve all got a little buzz going on. With their new automated laser, the team behind VibroSight++ believes they can exploit this fact to make city-scale sensing far cheaper and easier than ever before.

The key to the system is a turret mounted Class 3B infrared laser and photodetector that can systematically scan for and identity reflective surfaces within visual range. Now you might think that such a setup wouldn’t get much of a signal from the urban landscape, but as it so happens, the average city block is packed with retroreflectors. From street signs to road studs and license plates, the team estimates dense urban areas have approximately 7,000 reflectors per square kilometer. On top of those existing data points, additional reflectors could easily be added to particularly interesting devices that city planners might want to monitor.

Once VibroSight++ has identified its targets, the next step is to bounce the laser off of them and detect the minute perturbations in the returned signal caused by vibrations in the reflector. In the video below you can see how this basic concept could be put to practical use in the field, from counting how many cars pass over a certain stretch of road to seeing how popular a specific mailbox is. There’s a whole world of information out there just waiting to be collected, all without having to install anything more exotic than the occasional piece of reflective tape.

If this technology seems oddly familiar, it’s probably because we covered the team’s earlier work that focused (no pun intended) on using reflected laser beams for home automation in 2018. Back then they were aiming a much smaller laser at blenders and refrigerators instead of license plates and street signs, but the concept is otherwise the same. While we’ll admit the technology does give off a distinctive Orwellian vibe, it’s hard not to be intrigued by the “Big Data” possibilities afforded by the team’s upgraded hardware and software.

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