Drop-in Laser Cutter Alignment Beam Works like a Charm

Every laser cutter enthusiast eventually pops the question: how on earth do I align an invisible beam that’s more-than-happy to zap my eyeballs, not to mention torch everything else in its path? We hate to admit it, but laser cutter beam alignment is no easy task. To greatly assist in this endeavor, though, some folks tend to mix a red diode laser into the path of the beam. Others temporarily fixture that diode laser directly in the beam path and then remove it once aligned.

One deviant has taken diode laser mixing to the next level! [Travis Reese] has added a servo-driven diode laser that dynamically drops into the path of the laser tube when the lid pops up, and then tilts comfortably out of the laser path when the lid closes again.
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Aligning Invisible Lasers on-the-cheap

Lining up the beam from your homebrew (or retrofitted) laser cutter doesn’t come without its challenges. For instance, how do I use my remaining eye to align an invisible beam that has enough power to burn through some objects in its path? Some of us will go through the extra hassle and expense of mixing in a visible guide that traces the path of the CO2 laser. For the penny-pinchers out there, though, [Stephen] has us covered with an inexpensive technique that will cut you down by only a few strips of masking tape.

Stephan’s technique is simple, but elegant. He covers each mirror with tape, fires the laser, and leaves a burn mark, working his way from the last mirror that the laser hits to the first. With a burn mark on each mirror, and one through a guide made from a sheet of plywood, [Stephen] has a pretty good idea where the native direction of the beam is headed. He then swaps a red dot laser in to line up with the burn marks, and then aligns the mirrors using visible, and safe, light. Phew! Now that’s a lot easier than iteratively firing the beam and replacing the tape on the mirror each time we want to tweak the mirror alignment.

With all that burnt masking tape, the process can get a bit smelly. Nevertheless, we’ve filed this one away for later when we start getting that itching, burning sensation that kicks us into building our own homebrew laser cutter.

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