galvo

9 Articles

Custom built RGB laser firing beam

Lasers, Galvos, Action: A Quest For Laser Mastery

November 22, 2024 by 1 Comment

If you’re into hacking hardware and bending light to your will, [Shoaib Mustafa]’s latest project is bound to spike your curiosity. Combining lasers to project multi-colored beams onto a screen is ambitious enough, but doing it with a galvanomirror, STM32 microcontroller, and mostly scratch-built components? That’s next-level tinkering. This project isn’t just a feast for the eyes—it’s a adventure of control algorithms, hardware hacks, and the occasional ‘oops, that didn’t work.’ You can follow [Shoaib]’s build log and join the journey here.

The nitty-gritty is where it gets fascinating. Shoaib digs into STM32 Timers, explaining how modes like Timer, Counter, and PWM are leveraged for precise control. From adjusting laser intensity to syncing galvos for projection, every component is tuned for maximum flexibility. Need lasers aligned? Enter spectrometry and optical diffusers for precision wavelength management. Want real-time tweaks? A Python-controlled GUI handles the instruments while keeping the setup minimalist. This isn’t just a DIY build—it’s a work of art in problem-solving, with successes like a working simulation and implemented algorithms along the way.

If laser projection or STM32 wizardry excites you, this build will inspire. We featured a similar project by [Ben] back in September, and if you dig deep into our archives, you can eat your heart out on decades of laser projector projects. Explore Shoaib’s complete log on Hackaday.io. It is—literally—hacking at its most brilliant.

Laser Fault Injection On The Cheap

August 9, 2024 by 8 Comments

One can only imagine the wonders held within the crypto labs of organizations like the CIA or NSA. Therein must be machines of such sophistication that no electronic device could resist their attempts to defeat whatever security is baked into their silicon. Machines such as these no doubt bear price tags that only a no-questions-asked budget could support, making their techniques firmly out of reach of even the most ambitious home gamer.

That might be changing, though, with this $500 DIY laser fault injection setup. It comes to us from Finnish cybersecurity group [Fraktal], who have started a series of blog posts detailing how they built their open-source reverse-engineering rig. LFI is similar to other “glitching” attacks we’ve covered before, such as EMP fault injection, except that a laser shining directly on a silicon die is used to disrupt its operation rather than a burst of electromagnetic energy.

Since LFI requires shining the laser very precisely on nanometer-scale elements of a bare silicon die, nanopositioning is the biggest challenge. Rather than moving the device under attack, the [Fraktal] rig uses a modified laser galvanometer to scan an IR laser over the device. The galvo and the optical components are all easily available online, and they’ve started a repo to document the modifications needed and the code to tire everything together.

Of course, this technique requires the die in the device under study to be exposed, but [Fraktal] has made that pretty approachable too. They include instructions for milling away the epoxy from the lead-frame side of a chip, which is safer for the delicate structures etched into the top of the die. The laser can then shine directly through the die from the bottom. For “flip-chip” packages like BGAs, the same milling technique would be done from the top of the package. Either way, we can imagine a small CNC mill making the process safer and quicker, even though they seem to have done pretty well with a Dremel.

This looks like a fantastic reverse engineering tool, and we’re really looking forward to the rest of the story.
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Interesting Optics Make This Laser Engraver Fit In A Pocket

July 24, 2022 by 37 Comments

We’re going to start this post with a stern warning: building a laser engraver that can fit in your pocket is probably not a wise idea. Without any safety interlocks and made from lightweight components as it is, this thing could easily tip over and sear a retina before you’d even have time to react. You definitely should not build this, or even be in the same room with it. Got it?

Safety concerns aside, [DAZ] has taken a pretty neat approach to making this engraver, eschewing the traditional X-Y gantry design in favor of something more like the galvanometers used for laser projectors, albeit completely homebrew and much, much slower than commercial galvos. Built mostly of 3D-printed parts, the scanning head of this engraver uses a single mirror riding on an angled block attached to gimbals with two degrees of freedom. The laser module and mirror gimbals are mounted on a stand made of light aluminum so that the whole thing is suspended directly over a workpiece; the steppers slew the mirror to raster the beam across the workpiece and burn a design.

The video below shows it at work, and again, we have to stress that this is about as close to this build as you should get. It shouldn’t be too hard to add some safety features, though — at a minimum, we’d like to see a tilt-switch that kills power if it’s knocked over, and maybe some kind of enclosure. Sure, that would probably spoil the pocketability of the engraver, but is that really a feature valuable enough to risk your eyesight for?

If there’s a laser build in your future, please read our handy guide to homebrew laser cutter safety — before you can’t.

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Collaborative Effort Gets Laser Galvos Talking G-Code

July 15, 2022 by 9 Comments

Everyone should know by now that we love to follow up on projects when they make progress. It’s great to be able to celebrate accomplishments and see how a project has changed over time. But it’s especially great to highlight a project that not only progresses, but also gives back a little to the community.

That’s what we’re seeing with [Les Wright]’s continuing work with a second-hand laser engraver. It was only a few weeks ago that we featured his initial experiments with the eBay find, a powerful CO2 laser originally used for industrial marking applications. It originally looked like [Les] was going to have to settle for a nice teardown and harvesting a few parts, but the eleven-year-old tube and the marking head’s galvanometers actually turned out to be working just fine.

The current work, which is also featured in the video below, mainly concerns those galvos, specifically getting them working with G-code to turn the unit into a bit of an ad hoc laser engraver. Luckily, he stumbled upon the OPAL Open Galvo project on GitHub, which can turn G-code into the XY2-100 protocol used by his laser. While [Les] has nothing but praise for the software side of OPAL, he saw a hardware hole he could fill, and contributed his design for a PCB that hosts the Teensy the code runs on as well as the buffer and line driver needed to run the galvos and laser. The video shows the whole thing in use with simple designs on wood and acrylic, as well as interesting results on glass.

Of course, these were only tests — we’re sure [Les] would address the obvious safety concerns in a more complete engraver. But for now, we’ll just applaud the collaboration shown here and wait for more updates.

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Inside An EBay Marking Laser

June 11, 2022 by 13 Comments

When it comes to trolling eBay for cool stuff, some people have all the luck. Whereas all we ever seem to come across is counterfeit chips and obviously broken gear listed as, “good condition, powers on”, [Les Wright] actually managed to get more than he bargained for with one of his recent eBay purchases.

In his video teardown and tour of an industrial marking laser, [Les] suggests that he was really just in it for the optics — which is not a surprise, given his interest in optics in general and lasers in particular. The 20-W CO2 laser once etched barcodes and the like into products on assembly lines, but with a 2009 date code of its own, it was a safe bet that it was pitched due to a burned-out laser tube. But there were still high-quality IR optics and a precision X-Y galvanometer assembly to be harvested, so [Les] pressed on.

The laser itself ended up being built around a Synrad RF-stimulated CO2 tube. By a happy accident, [Les] found that the laser actually still works, at least most of the time. There appears to be an intermittent problem with the RF driver, but the laser works long enough to release the magic smoke from anything combustible that gets in its way. The galvos work too — [Les] was able to drive them with a Teensy and a couple of open-source libraries.

Galvos, lenses worth more than $800, and a working laser tube — not a bad haul. We’ll be following along to see what [Les] makes of this booty. Continue reading “Inside An EBay Marking Laser” →

Old Printer Becomes Direct Laser Lithography Machine

March 22, 2022 by 22 Comments

What does it take to make your own integrated circuits at home? It’s a question that relatively few intrepid hackers have tried to answer, and the answer is usually something along the lines of “a lot of second-hand equipment.” But it doesn’t all have to be cast-offs from a semiconductor fab, as [Zachary Tong] shows us with his homebrew direct laser lithography setup.

Most of us are familiar with masked photolithography thanks to the age-old process of making PCBs using photoresist — a copper-clad board is treated with a photopolymer, a mask containing the traces to be etched is applied, and the board is exposed to UV light, which selectively hardens the resist layer before etching. [Zach] explores a variation on that theme — maskless photolithography — as well as scaling it down considerably with this rig. An optical bench focuses and directs a UV laser into a galvanometer that was salvaged from an old laser printer. The galvo controls the position of the collimated laser beam very precisely before focusing it on a microscope that greatly narrows its field. The laser dances over the surface of a silicon wafer covered with photoresist, where it etches away the resist, making the silicon ready for etching and further processing.

Being made as it is from salvaged components, aluminum extrusion, and 3D-printed parts, [Zach]’s setup is far from optimal. But he was able to get some pretty impressive results, with features down to 7 microns. There’s plenty of room for optimization, of course, including better galvanometers and a less ad hoc optical setup, but we’re keen to see where this goes. [Zach] says one of his goals is homebrew microelectromechanical systems (MEMS), so we’re looking forward to that.

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Laser Galvos And An ESP32 Recreate Old-School Asteroids

February 18, 2021 by 21 Comments

Playing Asteroids now isn’t quite what it used to be when it came out 40 years ago. At the time, the vector-scan display was part of the charm; making do with an emulator running on a traditional raster display just doesn’t quite do it for purists. But if you manage to build your own laser-projector version of the game like [Chris G] did, you’re getting close to capturing some of the original magic of the game.

There’s a lot to unpack about this project, and the video below does a good job explaining it. Where the original game used a beam of electrons flashing inside a CRT to trace out each object in the game, [Chris] substituted an off-the-shelf two-axis galvanometer from eBay and a 5-mW laser LED. This can project a gamefield on a wall up to two meters on a side, far bigger than any version of the machine ever built. The galvos are driven by op-amp drivers and an SPI DAC on a custom PCB. And in comparison to the discrete logic chips and 6502 running the original game, [Chris] opted for an ESP32.

As interesting as the hardware for this is, the real story is in the software. [Chris] does an excellent job running through his design, making the bulk of the video feel like a master class in game programming. His software is from scratch — no emulations here. As such it doesn’t perfectly reproduce the original games — no flying saucers and no spaceship explosion animations (yet) — but when coupled with the laser vector display, it certainly captures the feel of the original.

Being devoted Asteroids fans from back in the day, this one really pushes our buttons. We’ve seen laser-based recreations of the game before, but this one makes us think we can finally afford to recapture the glory of our misspent youth.

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