Laser Hacks

641 Articles

DIY Laser For Ablating Metal

July 17, 2023 by 51 Comments

For those who wish to go beyond through-hole construction on perfboard for their circuit boards, a printed circuit board is usually the next step up. Allowing for things like surface-mount components, multi-layer boards, and a wider array of parts, they are much more versatile but do have a slight downside in that they are a little bit harder to make. There are lots of methods for producing them at home or makerspace, though, and although we’ve seen plenty of methods for their production like toner transfer, photoresist, and CNC milling, it’s also possible to make them using laser ablation, although you do need a special laser to get this job done.

The problem with cutting copper is that it reflects infra-red, so a higher-wavelength blue green laser is used instead. And because you want to ablate the copper, but not melt the surrounding areas or cut straight through the board, extremely short, high-power pulses are the way to go. Here, the [Munich Fab Lab] is using 9 kW pulses of around 30 microseconds each.  With these specifications the copper is ablated from the surface of the board allowing for fine details in the range of about 20 µm, which is fine enough for just about any circuit board. The design of the laser head itself is worth a look.

Aside from the laser, the rest is standard CNC machine fodder, but with an emphasis on safety that’s appropriate for a tool in a shared workspace, and the whole project is published under an open license and offers an affordable solution for larger-scale PCB production with extremely fine resolution and without the need for any amounts of chemicals for the more common PCB production methods. There is a lot more information available on the project’s webpage and its GitHub page as well.

Of course, there are other methods of producing PCBs by laser if you happen to have a 20 W fiber laser just kicking around.

No Moving Parts LiDAR

July 6, 2023 by 29 Comments

Self-driving cars often use LiDAR — think of it as radar using light beams. One limitation of existing systems is they need some method of scanning the light source around, and that means moving parts. Researchers at the University of Washington have created a laser on a chip that uses acoustic waves to bend the laser, avoiding physically moving parts. The paper is behind a paywall, but the University has a summary poster, and you can also find an overview over on [Geekwire].

The resulting IC uses surface acoustic waves and can image objects more than 100 feet away. We would imagine this could be helpful for other applications like 3D scanning, too. The system weighs less than a conventional setup, too, so that would be valuable in drones and similar applications.

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Growing Simple Crystals For Non-Linear Optics Experiments

July 6, 2023 by 18 Comments

Here’s an exercise for you: type “crystals” into your favorite search engine and see what you get. If you’re anything like us, you’ll get a bunch of pseudoscientific posts about the healing power of crystals, along with offers to buy the same at exorbitant prices. But woo-woo aside, certain crystals do have seemingly magical powers — like the ability to turn light from one color into another.

None of this is magic, of course. Rather, as optics aficionado [Les Wright] explains, non-linear optics is all about physics. Big physics, too, like the kind that made the National Ignition Facility the first fusion research outfit to reach the “break-even” point, at least in terms of optical energy. To do so, they need to convert megajoules of infrared laser beams all the way across the visible spectrum into the ultraviolet, relying on huge crystals of deuterated potassium dihydrogen phosphate (KDP) to do so. Depending on how they’re cut, crystals of these sorts have non-linear optical properties like second-harmonic generation, which combines two input photons into a single output photon with twice the energy of the original. This results in a halving of the wavelength of the input, which doubles the frequency.

While the process used at the NIF produces crystals of enormous proportions, [Les] has more modest needs and thus a simpler process. His KDP is an off-the-shelf chemical, nothing fancy about it, which is added to boiling water to make a saturated solution. A little of the solution is poured out into a watch glass to make seed crystals, and everything is allowed to cool slowly. A nice seed crystal is glued to a piece of monofilament fishing line and suspended in the saturated solution, and with enough time a good-sized crystal forms. Placed into the beam path of a 1,064 nm IR laser and rotated carefully relative to the beam, the crystal easily produces a brilliant green laser output.

This is fascinating stuff, and we’re looking forward to seeing where [Les] goes with this. Polishing the crystals to make them optically cleaner would be a good next step, as would perhaps growing even larger crystals.

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TeraByte InfraRed Delivery (TBIRD)

NASA Team Sets New Space-to-Ground Laser Communication Record

June 9, 2023 by 13 Comments

[NASA] and a team of partners has demonstrated a space-to-ground laser communication system operating at a record breaking 200 gigabit per second (Gbps) data rate. The TeraByte InfraRed Delivery (TBIRD) satellite payload was designed and built by [MIT Lincoln Laboratory]. The record of the highest data rate ever achieved by a space-to-Earth optical communication link surpasses the 100 Gbps record set by the same team in June 2022.

TBIRD makes passes over an ground station having a duration of about six-minutes. During that period, multiple terabytes of data can be downlinked. Each terabyte contains the equivalent of about 500 hours of high-definition video. The TBIRD communication system transmits information using modulated laser light waves. Traditionally, radio waves have been the medium of choice for space communications. Radio waves transmit data through space using similar circuits and systems to those employed by terrestrial radio systems such as WiFi, broadcast radio, and cellular telephony. Optical communication systems can generally achieve higher data rates, lower loses, and operate with higher efficiency than radio frequency systems. Continue reading “NASA Team Sets New Space-to-Ground Laser Communication Record” →

Easy Graphene Production With A Laser Engraver

May 20, 2023 by 13 Comments

Graphene isn’t easy to produce at scale. But making small batches of graphene is doable in a few ways. [Robert Murray-Smith] decided to try producing “flash graphene.” This requires a big capacitor bank that is moderately expensive, so he decided to explain a different technique he read about using an ordinary laser cutter. Check it out in the video below.

We were a little disappointed that he didn’t actually make any graphene this time. He has, however, used other methods in other videos to create some type of graphene. In fact, he has many similar videos going back quite a ways as well as applications with concrete, capacitors, and more. We understand that this method doesn’t produce monolayer graphene, but actually creates a graphene “foam” with interesting properties. [Robert] talks about recent papers that show you can grow graphene on things other than Kapton tape using this method.

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Modern CO2 Laser Reviewed

May 15, 2023 by 14 Comments

If you’ve got a laser cutter, it is highly probable that it uses a laser diode. But more expensive machines use a carbon dioxide laser tube along with mirrors. There was a time when these lasers came in two flavors: very expensive and amazing or moderately expensive and cheaply made. However, we are seeing that even the moderately expensive machines are now becoming quite advanced. [Chad] reviews a 55-watt xTool P2. At around $5,000, it is still a little spendy for a home shop, but it does have pretty amazing features. We can only hope some less expensive diode lasers will adopt some of these features.

[Chad’s] video that you can see below attempts to recreate some of the amazing things xTool did on their product introduction live stream. He was able to recreate most, but not all of the results. In some cases, he was also able to do better.

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Artemis II Laser Communications

Artemis II Will Phone Home From The Moon Using Laser Beams

May 14, 2023 by 52 Comments

[NASA] Astronauts will be testing the Orion Artemis II Optical Communications System (O2O) to transmit live, 4K ultra-high-definition video back to Earth from the Moon. The system will also support communication of images, voice, control channels, and enhanced science data.

Aboard Orion, the space terminal includes an optical module, a modem, and a control system.  The optical module features a four inch telescope on a dual gimbal mount. The modem modulates digital information onto laser beams for transmission back to Earth, and demodulates data from laser beams recieved from Earth. The control system interfaces with avionic systems aboard Orin to control and point the communications telescope.

On Earth, facilities including the Jet Propulsion Laboratory and the White Sands Complex will maintain high-bandwidth optical communication links with Orion. Information received from Orion will be relayed to mission operations, scientists, and researchers.

NASA’s Laser Communications Relay Demonstration (LCRD) showcases the benefits of optical communications.  Traditionally, missions relied upon radio communication, but improved technology will better serve space missions that generate and collect ever-increasing quantities of data. Optical communication solutions can provide 10 to 100 times the bandwidth of radio frequency systems. Other improvements may include increased link distances, higher efficiency, reduced interference, improved security, and reductions in size and weight. Our Brief History of Optical Communication outlines many of these advantages.

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